2K Plastic Injection Mold

Challenge: Three simultaneous risks surfaced during DFM review: (1) transparent melt eroding black substrate causing flow marks in window area, (2) weld lines forming where clear material converges at button protrusions, (3) multiple undercuts in rear door zone posing high demolding failure risk.

Solution: Instead of jumping straight to production tooling, we ran structured pre-validation — mold flow simulation for melt-front interaction, gate relocation to shift weld line off visible surfaces, and collapsible core design for rear door undercuts — eliminating all three risks before cutting steel.

Result: First trial success. Appearance and structural dimensions all passed inspection. Small-batch validation completed, mold delivered on schedule with zero rework. A project that could have been derailed by hidden risks — shipped clean.