Injection-moulded bracket, design for manufacture

A coursework part taken all the way to a real tool, which is where you find out what your CAD was hiding.

Bracket 01 parts
Category University
Where Manufacturing processes, MEC-214
Year 2025
My part Part design, tool design, moulding trials
Result Walls 2.0-2.4 mm, no sink after revision two

The exercise was to take one bracket from sketch to moulded part on the department's bench press. Mine held a sensor on a frame, so it needed stiffness in one direction and almost none in the other.

The first tool gave me sink marks exactly where I had been warned they would appear. Version two moved the boss off the thick section and added a rib, which fixed it. Wall thickness stayed inside 2.0 to 2.4 mm across the part.

I kept every reject on my desk for a term. They are better teachers than the good ones.