We believe DFM (Design for Manufacturing) is the most important part of a successful project. It’s where overlapping relationships between price, speed, and quality align to form a clear project blueprint. In a perfect world, the part designer and tool designer have the same social security number and a polymer science degree to boot. Typically, that’s not the case. Call in the Cavalry! We’ve seen it all. Below is a quick look at our DFM process and the depth of our collaborative approach.
RESIN
Material should be an early priority, but often happens deep into the part design. Let us evaluate your options early to make sure we’re aligned with your goals.
TOOL MATERIAL
Do you want it to last, or do you want it fast? We help strike a balance with resin characteristics, production volumes, and deadlines in mind.
TOOL ACTION
We flex our problem-solving skills here. Modular inserts, specialty slides, gate shutoffs, and swappable cores are commonplace for us. Not sure of the benefits? Let’s talk!
PARTING LINE
Where cavity meets core. This will give your CAD designer nightmares if identified too late. Easy enough to determine, so take care of it early.
GATE SCHEME
Injection point details are crucial. With a library of options to choose from we walk you through how it might affect part price, cosmetics, and dimensional control.
DRAFT EVALUATION
Each resin and texture pattern is associated with recommended draft requirements. Understanding the relationship can help avoid scuffs and deformation.
THICKNESS ANALYSIS
Uniform wall thickness is a given, however, each resin has different flow guidelines and some design features have unique exceptions. We’ll set up the bumpers so you don’t end up in the gutter.
EJECTION PATTERN
How does the part separate from the tool? We prefer quick and easy. We’ll lay out an efficient pattern specifically for you.
TEXTURE EVALUATION
Looking for A1 polish or Mold-Tech textures? We got you. You want alligator skin texture? We also got you… and are very intrigued!
VENTING
Proper venting preparation keeps air trap defects at bay. This step helps us locate them before they cause any trouble.
WELD LINES
Molten resin under high pressure can stress polymers, causing cracks and witness lines. We'll locate problem areas and suggest design refinements to avoid them altogether.
WARPAGE
No one wants their flat part coming out looking like a potato chip. We’ll evaluate the resin, fill-time, and injection point locations to make sure your parts are flat as hell.
Raw and Real. When you need it yesterday and shot with the end-production resin—our Modular Unit Die (MUD) program has you covered.
BRIDGE TOOLING
Curated tools built with your unique requirements in mind. Removable cores, specialty action, reverse ejection—you name it, we’re Onit.
PRODUCTION TOOLING
Keep it simple. You’ve ID’d your tool SPI classifications. Whether it’s production or export—we make it happen.
COMMON INJECTION MOLDING MATERIALS
Material selections can feel overwhelming with over 80,000 unique injection molding resins to choose from. It’s important we identify the right material early. Our team of experts will help you find the right resin or polymer for your unique needs. The top 8 most commonly used resins are outlined below.
01. PA or Nylon
Known for high mechanical properties, elasticity, toughness, and resistance to wear. Used in durable mechanical components such as bushings, gears, and automotive applications.
02. ABS
Known for great impact resistance, toughness, and ease of molding. Used for computer housings, musical instruments, automotive components, and more.
03. PS or Polystyrene
Two types—General Purpose Polystyrene (GPPS) and High Impact Polystyrene (HIPS). Applied in packaging, disposable containers, and other consumer goods.
04. PC or Polycarbonate
Known for clarity, impact resistance, transparency, and toughness. Used in applications such as eyewear lenses, consumer electronics, and medical devices.
05. POM or Acetal
Known for high stiffness, low friction, and excellent dimensional stability. Suitable for precision parts such as automotive and consumer electronics.
06. PMMA or Acrylic
Known for excellent clarity and resistance to UV light. Clear, glass-like polymer used in high light transmission applications such as automotive headlights and displays.
07. PE or Polyethylene
Known for flexibility and chemical resistance. Commonly used in containers, household goods, and packaging. Varieties include HDPE and LDPE.
08. PP or Polypropylene
Known for chemical and electrical resistance, elasticity, and high melting point. Widely used in automotive parts, containers, and textiles.
03. PS or Polystyrene
Two types—General Purpose Polystyrene (GPPS) and High Impact Polystyrene (HIPS). Applied in packaging, disposable containers, and other consumer goods.
04. PC or Polycarbonate
Known for clarity, impact resistance, transparency, and toughness. Used in applications such as eyewear lenses, consumer electronics, and medical devices.
05. POM or Acetal
Known for high stiffness, low friction, and excellent dimensional stability. Suitable for precision parts such as automotive and consumer electronics.
06. PMMA or Acrylic
Known for excellent clarity and resistance to UV light. Clear, glass-like polymer used in high light transmission applications such as automotive headlights and displays.
07. PE or Polyethylene
Known for flexibility and chemical resistance. Commonly used in containers, household goods, and packaging. Varieties include HDPE and LDPE.
08. PP or Polypropylene
Known for chemical and electrical resistance, elasticity, and high melting point. Widely used in automotive parts, containers, and textiles.
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TESTIMONIALS
Whether it's additive or subtractive, it's collaborative. See for yourself.
“We reached out to Onit for support on a cost-reduction initiative for one of our overly complex assemblies. The Onit team was instrumental in redesigning several components from metal to plastic, and they even helped consolidate a few part numbers, which streamlined our BOM and ultimately lowered our overall costs."
Brian Willebrand
Director of Engineering
Modern Process Equipment
"Onit Mfg has been one of the most communicative and accountable vendors that I've worked with. Where they shine is their excellent communication and customer service, as well as their ability to address complex manufacturing challenges."
Julie Kumar
Supply Chain Manager
Pyka
We came to Onit Mfg with a project that had been continuously no-bid by other suppliers. They quickly identified the challenges and provided innovative solutions for our unique project requirements. The time and engineering resources we saved working with this team is invaluable - We couldn’t have found a better partner."
