When it comes to developing a new product, prototyping is one of the most important steps you can take. It’s how you test your assumptions, catch design problems early, and build confidence in your concept before committing to full-scale manufacturing.

The challenge is that traditional prototyping methods can be slow, expensive, and labour-intensive. That’s exactly where 3D print prototyping changes the game.

At Dienamics, we use 3D print prototyping to help our clients move faster, spend smarter, and get better results from the development process. Here’s why it’s become one of the most valuable tools in modern product development.

What Is 3D Print Prototyping?

3D print prototyping combines the speed of rapid prototyping with the precision and accessibility of 3D printing technology. Using a CAD file of your design, a 3D printer builds your prototype layer by layer, producing a physical model that can be tested, evaluated, and refined.

The result is a tangible representation of your product that you can hold, assess, and make decisions from, without the time and cost associated with traditional manufacturing methods.

The Advantages of 3D Print Prototyping

Fast Turnaround Times

One of the biggest advantages of 3D print prototyping is speed. At Dienamics, we can typically deliver a 3D printed prototype in less than a week, provided you have a CAD model ready to go. For more complex or highly aesthetic models, turnaround is generally around two weeks.

That speed matters more than it might seem. The faster you have a physical prototype in hand, the faster you can test it, identify issues, and move into the next iteration. In product development, time is one of your most valuable resources, and 3D printing gives you more of it to spend on refinement rather than waiting.

Lower Costs

Because 3D print prototyping is faster and requires fewer resources than traditional methods, it tends to cost significantly less. There’s no need for multiple machines, complex tooling setups, or large teams to produce a single prototype. The process is largely automated once your CAD file is ready, which reduces both labour and machine costs.

This makes it far more practical to run multiple iterations of a design. Rather than committing to one prototype and hoping it’s right, you can test, refine, and retest without blowing your development budget.

Seamless CAD Integration

3D print prototyping fits naturally into a modern product design workflow. If your design exists as a CAD file, you can go directly from screen to physical prototype without the manual programming, setup, or toolpath creation required by traditional subtractive methods like CNC machining.

This streamlined process eliminates a significant amount of friction from the prototyping stage. It means fewer handoffs, less room for error in translation, and a much shorter path from design decision to physical result.

It’s worth noting that 3D printing isn’t always the right choice over CNC machining. Each process has its strengths depending on the material, geometry, and purpose of the prototype. But for early-stage concept validation and iterative testing, 3D printing is hard to beat for speed and accessibility.

Wide Range of Materials

One of the less obvious advantages of 3D print prototyping is the material flexibility it offers. Depending on what you need to test, whether that’s structural integrity, flexibility, appearance, or fit, there’s likely a material suited to the job.

At Dienamics, we work with a range of materials including:

• ABS: durable and impact-resistant, great for functional testing
• ASA: similar to ABS but with better UV resistance
• PC (Polycarbonate): high strength and temperature resistance
• PC-ABS: a blend offering the best of both materials
• PLA: easy to print and ideal for visual models
• PETG: strong, flexible, and food-safe
• Nylon: excellent for wear resistance and mechanical parts
• TPU: flexible and rubber-like, suited to parts that need to bend or compress

Having access to this range means your prototype can closely mimic the properties of the intended production material, making your testing results far more meaningful.

Run Tests Easily

3D printed prototypes can be mechanically functional, purely aesthetic, or somewhere in between, depending on what you need from a given round of testing. This flexibility means you can gather real feedback from stakeholders, end users, or your own engineering team at almost any point in the development process.

Getting a physical prototype in front of real users early is one of the most effective ways to identify issues that simply don’t show up on screen. It also makes it much easier to communicate your product vision to investors, retail buyers, or manufacturing partners.

Ready to Prototype Your Product?

If you’ve got a concept that’s ready to be tested, 3D print prototyping is one of the smartest investments you can make in your product’s development. At Dienamics, our Brisbane-based team can take your CAD file and turn it into a physical prototype quickly, cost-effectively, and with the material properties your testing requires.

Get in touch with our team to find out how we can help you move from concept to prototype, fast.

The post 3D Print Prototyping: Why Should You Use It? appeared first on Dienamics.

What’s the difference between rapid prototyping and 3D printing?

If you’ve spent any time researching product development, you’ve probably seen rapid prototyping and 3D printing used interchangeably. It’s an easy mistake to make, but the two terms actually mean different things. Understanding the distinction will help you make better decisions about how to develop and test your product.

Here’s the short version: rapid prototyping is the goal, and 3D printing is one of the methods you can use to achieve it.

What Is Rapid Prototyping?

Rapid prototyping is the process of quickly producing a physical model of a product so you can test, evaluate, and refine the design. The emphasis is on speed. Rather than waiting weeks or months to see your concept in physical form, rapid prototyping gets something in your hands fast so you can start learning from it.

There are several methods used to rapidly prototype a product, including 3D printing, CNC machining, and vacuum casting. Each has its own strengths depending on what you need to test, what material properties matter, and how close to the final product you need the prototype to be.

Prototypes generally fall into two categories:

Low-fidelity prototypes have noticeable differences from the final product. These are useful in the early stages when you’re testing a concept or getting a rough sense of form and scale, and precision isn’t the priority yet.

High-fidelity prototypes closely match the intended final product in terms of appearance, material properties, or function. These are used later in the development process when you need reliable data from testing or want to present something close to production-ready.

Rapid prototyping is valuable at almost every stage of product development. Having a physical model helps designers and engineers identify problems that don’t show up on screen, and it gives clients something tangible to respond to, which tends to produce much more useful feedback than looking at a CAD render.

What Is 3D Printing?

3D printing is a type of additive manufacturing. Additive manufacturing refers to any process that builds a 3D object by adding material layer by layer, as opposed to subtractive methods like CNC machining, which start with a block of material and remove what isn’t needed.

In 3D printing, a CAD file directs the printer to deposit material in precise layers until the object is complete. The process is largely automated once the file is prepared, which is a big part of what makes it so fast and accessible.

There are several types of 3D printing technology, each suited to different applications. FDM (Fused Deposition Modelling) is the most common and works by extruding melted plastic through a nozzle. SLA (Stereolithography) uses a UV laser to cure liquid resin into solid layers, producing smoother and more detailed results. SLS (Selective Laser Sintering) uses a laser to fuse powdered material, making it well suited to functional parts with complex geometries.

So What’s the Difference?

Rapid prototyping is a strategy. 3D printing is a tool.

When someone says they want to rapidly prototype their product, they’re describing an approach to development: fast iteration, physical testing, learning quickly. When someone says they want to 3D print a prototype, they’re describing the specific method they’ll use to produce it.

3D printing is often the preferred method for rapid prototyping because it’s fast, relatively affordable, and works directly from a CAD file without the need for tooling or complex setup. But it isn’t always the right choice. For parts that need to closely replicate the mechanical properties of a production material, CNC machining or vacuum casting may be more appropriate. The best method depends on what you’re testing and what you need the prototype to do.

When Should You Use 3D Printing for Prototyping?

3D printing tends to be the best option when:

• You need a prototype quickly and have a CAD file ready to go
• You’re testing form, fit, or early-stage function rather than final material performance
• You want to run multiple iterations without significant cost per round
• You need to communicate your design concept to stakeholders or investors

It’s worth discussing your specific requirements with your design and prototyping team before committing to a method. The right choice at the start of development may be different from what’s needed three rounds later.

Prototyping With Dienamics

At Dienamics, rapid prototyping is a core part of how we develop products. We work with our clients to determine the right prototyping method for each stage of development, whether that’s 3D printing, CNC machining, vacuum casting, or a combination of approaches.

If you’re ready to take your concept to the next stage, get in touch with our Brisbane team to find out how we can help.

The post The Difference Between Rapid Prototyping and 3D Printing appeared first on Dienamics.

• How do I get into industry?
• What skills do I need to learn as a product designer or industrial designer?
• Which CAD software is used most in industry?
• How do I get an industrial design job?

If you’re studying Industrial Design, these are no doubt the main questions running through your head as you make it through your degree. These were my main questions before landing a job here at Dienamics, so as a Junior Industrial Designer and Soon-to-Graduate Student, I wanted to share with you what I’ve learned so far.

If you want to learn more about design, the industry, and manufacturing, then make sure to read through the other articles here!

Tips for Industrial Design Students

Throughout your degree, you will build the essential skills an industrial designer uses every day, from sketching and 3D modelling to communication and project management. To get the most out of your degree and prepare yourself for industry, it is important to focus not just on technical tools, but also on your interpersonal skills and personal aspirations that make you unique and will set you apart.

So, what does this actually look like?

Sketching

As crazy technology continues to get more accessible, it is crucial to remember the importance of the most fundamental design tool: pen and paper. Sketching proficiency allows you to quickly get ideas onto paper, helping you process your own thinking while clearly communicating concepts to your clients or colleagues. A clean sketch can communicate design direction, aesthetics and context of use far more effectively than words or a paragraph and can ultimately be the thing that sells your concept. Focus on your clean linework and 3D geometry practise, practise, practise!

Computer-Aided Design (CAD) and 3D Modelling

With plenty of CAD software options out there, starting your 3D modelling journey can feel overwhelming. To help figure out which software is right for you, ask yourself these key questions:

• Is the form of my design more organic or geometric?
• Is my design a large assembly with a lot of parts?
• How important is the accuracy and control of measurements?

CAD software packages Blender, ZBrush, Autodesk Alias and Solidworks and a corresponding example of a 3D model made in that software. Please note the form variations across these 3D models, highlighting the strengths and specialisations of each CAD software: Blender and ZBrush – for digital sculping, Autodesk Alias – for complex surface modelling, and Solidworks – for parametric modelling with high geometric precision.

When moving into industry, every company is different and will often have specific software preferences.

As I mentioned earlier, the specific requirements of a project will often determine which CAD software is best suited. However, a company’s software preference is also dependent on additional factors such as budget and software availability. Solidworks is most common in larger in-house design teams, design firms and larger organisations. Smaller firms, however, may lean towards more cost-effective options such as Fusion 360, Inventor, or Onshape.

For most CAD models requiring suitability for manufacturing, Solidworks is most common. As we specialise in injection moulding and manufacturing at Dienamics, powerful parametric modelling with accurate geometric control and the ability for complex surface geometries are our highest priorities for CAD software, and Solidworks ticks those boxes. If you have an interest in product design and manufacturing, then spending as much time as possible in Solidworks and learning the requirements of DFM CAD is a great way to prepare yourself. Familiarising yourself with top-down modelling approaches using master or parent sketches will immediately make your workflow more sophisticated.

Also, taking the time to research different manufacturing methods and their corresponding design requirements is incredibly beneficial. As an example, injection moulding has a lot of strict requirements to make a product mouldable and significant design considerations to optimise the tooling and moulding process. This includes maintaining consistent wall thicknesses to improve material flow, removing undercuts to minimise tool complexity and designing to accommodate for certain geometries or materials to minimise warping, shrinkage, or rejected parts.

An example of 3D printed parts that would be impossible and or very difficult to injection mould in a single part without a redesign to optimise the part.

The “Passenger” Cup Holder designed by Dienamics and modelled in Solidworks, for Touring Essentials. One way this product was optimised for injection moulding was by maintaining consistent wall section throughout the part, designing the part with tool access in mind, to minimise the need for sliding actions to reach button and sliding cup tray holes, ensuring each face is precisely drafted, and adding ribs across the entire underside to increase the part’s rigidity.

While working in industry is without a doubt the best teacher – it certainly was for me – background research and practice can help you understand if it interests you, could open the door for some exciting opportunities and help soften the learning curve. Within our team of experienced tool makers, moulders and industrial designers, we at Dienamics are strong believers in the importance of manufacturing knowledge within the design space. Even if manufacturing isn’t a core interest for you, DFM knowledge can save you from unexpected and costly surprises when your design reaches a manufacturer. Whether that’s last-minute edits or, in the worst case, a complete redesign, applying this skill will save you and your clients time, stress and money, and ultimately make you a stronger industrial designer.

Design Thinking & Workflow

Concept sketching in the Dienamics office.

Learning the fundamentals of design at university may feel tedious but I cannot express how important these key themes are. Usability, ergonomics, and user experience are all themes that will likely start to seep into your everyday life, forcing you to subconsciously evaluate the products around you. This is a good thing! Experiencing the impacts of effective and ineffective product design reinforces the importance of good design in your own projects, allowing you to learn from objects around you and become a better designer.

University projects also provide the space to understand what process works for you and what doesn’t. Design processes are fluid and unique to each designer based on personal preference, discovering yours will allow you to work as efficiently as possible which is especially important once you start working on the clock. The better you can understand yourself through university and into your professional industrial design career, the more accurately you can plan, quote clients for your time and polish your design process.

As I am sure you know, university documentation is no walk in the park. Luckily, once you graduate, you may never need to do documentation to that level of detail ever again. However, in industry, effective documentation skills are important for:

• Tracking progress to ensure you meet deadlines
• Communicating progress to clients
• Backing your proposed concepts with evidence of ideation and refinement
• Ensuring your work is understandable if it needs to be revisited in the future by you or another designer

Though, an effective design process and good design is nothing without effective presentation.

Presentation and Communication

Successfully presenting your ideas is a huge part of being a designer, selling your ideas is just as important as coming up with them. Without clear visual communication, even your best work can look rushed, unfinished, or unprofessional; clean concept sketches and polished CAD renders are the final sells that bring your client’s vision to life.

Comparison of the CAD screenshot of the award-winning Baby Bot Bot Bottle Helper, designed by Baby Bot Bot and Dienamics.

Render of the Baby Bot Bot Bottle Helper, rendered in Keyshot. Please note the increase in perceived quality between the CAD screenshot to the professional render and how it changes the way the product is perceived.

Equally, strong communication skills beyond visuals are just as essential in industry. Collaborating with and receiving feedback from your colleagues often fosters the best design solutions by combining different ways of thinking. Similarly, the ability to back your ideas and justify the importance of specific design features to clients, your colleagues, or manufacturers will get your designs and ideas over the line.

For students, whether you’re sending an email, sitting in an interview, or working an internship, the impression you leave matters and your personal communication skills are ridiculously important. Nerves are normal, but authenticity, confidence (not arrogance), and a willingness to learn go a long way. Employers value people who can balance curiosity and initiative in the workplace, so ask considered questions, jump into every opportunity and gather as much constructive feedback as possible.

That being said, if you are truly feeling stuck, it is always better to ask for help. At the start of my internship, I too was worried about what my supervisors were thinking. However, from the eyes of your employer, spending hours staring at a blank screen is far worse than asking one “dumb” question. As a student, intern or junior, you are not expected to know everything. Admitting what you don’t know is not only better for your own learning but will also let your employer know how to help you.

Get out of the classroom!

Like most things, the best way to learn is to do it. No matter where you can get involved in the design process, be involved! From admin to manufacturing to design work: work experience, internships and part time work are all incredible opportunities to expand your expertise and develop your personal perspective as a designer. But how do you make these opportunities happen?

How do I get into the product design industry?

My biggest piece of advice is to simply put yourself out there! Making connections and reaching out can feel incredibly daunting, but it doesn’t have to be high pressure!

Here’s what I suggest:

Put yourself out there

Internships, part-time work, work experience are the most valuable things for a young designer. Experience creates understanding that is unable to be taught in a classroom, provides a leg up against your peers, and gives you a taste of what your life might look like after uni. You may be thinking “that’s easier said than done” – fair enough – but even the smaller steps like conversations with industry professionals, portfolio reviews, or partaking in industry inspired personal projects are stepping stones towards progressing your professional career. The worst they can do is say no, but most people are willing to help where they can!

Social media

Following and interacting with design or manufacturing companies on social media creates great opportunities to put your name on their radar. Liking, commenting and reposting are incredibly casual ways of networking with design companies you may be interested in. Social media is also the best way to keep up with what industry-standard work looks like, understand trends, connect the dots on who’s who in the industry, and find inspiration to potentially apply to your own projects.

Connect with your peers and your university

When you graduate, your entire university cohort turns into a group of people aspiring to or working in industry. Who knows, these connections could provide you with new opportunities for personal and/or professional growth. Also, your peers are a fantastic way to benchmark your personal skillset. Receiving critical feedback and reviewing other people’s projects will train your eye and make you better.

Personal projects

While the university workload is intense, finding time to work on personal projects is a great way to build a personal brand. Posting projects online is a great way to get your name out there and will stand out in your portfolio against a sea of university students with the same briefs. Also, projects inspired by companies you are interested in creates an opportunity to grab their attention or can simply give you a little more direction when assigning your own brief.

Three of our talented industrial design staff at Dienamics. (Left to right: Lara, Alex & Bryce)

Summary

So, here is what I would do if I were you:

• Understand your personal identity as a designer. What are you passionate about? What are your hobbies outside of design? And how does this shape your personal style, perspective and goals as an industrial designer?
• Practise, practise, practise! Think of your hard and soft skills as a muscle, the more you work it now the easier your transition into industry will be. Taking the time to develop a range of skills at university is extremely worthwhile, remembering not to neglect the basics like communication, documentation and sketching.
• Join the community. Learn what the design industry looks like through social media and community engagement, and always keep your eyes peeled for potential opportunities like personal projects, design challenges, or networking events!
• Put yourself out there. Get into industry as early as possible to understand the day-to-day life of an industrial designer. Whether you are behind a desk or on a workshop floor: all work experience is good experience.

Conclusion

To any aspiring industrial designers worrying about what they should be doing during university or how to get a product design job, the reality is: there is no right answer. Everyone’s professional journey will be different. By figuring out your goals and maybe taking a little bit of my advice, I hope you can come out of your degree with a clear direction and some potential strategies to help turn your passion into a career.

Want to learn a little bit more about the product design process and what industrial design looks like in industry? Take a look at this article!

At Dienamics, we offer a range of comprehensive services in every step of the product manufacturing process. These include:

• Product design, including concept assessment and project scoping
• Prototyping and process and materials testing
• Manufacturing, injection moulding, production, assembly, and packaging

Contact us today if you have a product you’re looking to design & manufacture!

The post Tips for Students from a Junior Industrial Designer appeared first on Dienamics.

Creating a brand behind your product can dramatically influence how well your product sells on the market. Branding is the best way to communicate your brands story, company’s values, and stand out in a market. For product design, we believe applying branding is vital to show off your unique identity and establish customer connection and loyalty. It differentiates you from other competitors which overall draws new customers, increased sales and a stronger market position. Branding can be more than aesthetics as it encompasses everything, from the connection you have to your customers and the company’s grounding values. This blog takes a deep dive into branding how it dictates the design and how it’s perceived, while also answering common questions like what is product design and how to design a product that connects with your audience.

Designing for The Better Brand’s cosmetic range required us to work with the company’s existing design language and ideas for branding. We brought Better Brand’s ideas to life by creating manufacturable injection moulded parts in a bright dual shade colour scheme. The colour of the plastic bottles reflects the contents aroma and formula, whilst the visual elements incorporate through embossing and pad printing provides information about the product.

Branding Dictates the Design

From colour to material, the branding choices can make or break your product 

Branding plays a huge role in how the customer first receives your product. First impressions matter…even when it comes to product design. A well-crafted logo, colour palette and material choice can capture attention and convey a brands personality in seconds. According to AMA, up to 90% of snap-judgements made about products are based on colour marketing alone. Unique and consistent visual elements such as logos or graphics make it easy for consumers to recognise your product and choose it. Even simple products that may not be direct consumer products, such as structural plastic parts, can still benefit from subtle branding, whether it’s a simple embossed logo, a colour change, or how an edge is finished, it draws the user’s eye. 

Nothing’s technology pushes the limits of innovative technology. Their unique transparent and simplistic design resonates with customers as it creates a sense of nostalgia and an intuitive experience. By combining a more humane approach to smartphones and giving the customer premium quality at a reasonable price, the tech range became popular very quickly.

The Power of the Logo

The logo is a requirement for brand recognition and trust.

Although the logo isn’t the essence of the brand, it’s the face of it. It serves to tie product lines together when it’s difficult to do so through design language alone. The logo embodies the brand in a single symbol, which can then be applied anywhere for brand recognition, subconsciously developing customer trust. It serves as a foundational visual cue that connects with consumers on an emotional level, influencing their purchasing decisions and fostering trust in the products offered. 

Having a cohesive logo applied across products, websites, apps, apparel and marketing material can make your brand instantly recognisable in a packed marketplace, helping you stand out from competitors and remain in consumers’ minds. 

A unique recognisable logo on a simple product can easily change how the customer views the quality and reputation of the product. Because in most cases, consumers are often going to reach for brands that they associate with quality and status. In a saturated market where many products look similar, the logo could be the differentiating point, as consumers are willing to pay more for the brand’s reputation, rather than the shirt’s material or manufacturing cost alone. This also highlights how to design a product that not only attracts attention but also builds long-term trust.

For example, two T- shirts side by side may be made in the exact same factory with the same materials, but one may sell for $10 where the other might sell for $80 if there is a Supreme logo on it.

Importance of Design Language

Design language looks past the logo to embody the brand in every detail 

An identifiable brand logo is necessary, but proper design language is just as important. The design language embodies the brand’s identity and embodies it through to every part and detail. If a designer’s done their job, you’ll be able to look at just small isolated part of the product, and tell what brand the product is from. From how an edge is finished, to the materials, textures and colours used, to the flatness or curve of the form, to the overall proportions of the product and use of blank, or cluttered space … The design language encapsulates the essence of the brand and proclaims that essence in the physical embodiment of the product. 

As an Industrial design company, we consider all these factors to develop or apply our customers’ design language, which is unique for every brand. Our designers look to develop visual and tactile elements to create a style for the product and its future product range, right from the start. The process includes user research, market research, sketching concepts to explore a range of forms and styles, using CAD models to get proportions right, and creating prototypes to ensure the overall product solves its target problem for the user, and communicates your brand’s personality. The entire approach reflects how to design a product and get it made, moving from early concepts through to finished designs.

Apple’s Human Interface Guidelines (HIG) prioritise a refined, elegant, and intuitive experience, focusing on clear, purposeful elements and natural motion within a unified system. In contrast, Google’s Material Design, particularly Material You, emphasises bold expression, user personalisation, modular flexibility, and dynamic animations that add depth and personality. While Apple’s approach aims for calm immersion and inherent functionality, Google’s design philosophy seeks to create expressive interfaces that adapt to individual preferences while maintaining structural coherence. (Image source: Simple Alpaca on Youtube)

Designing for your target market

Identifying your user group and designing for them

Once you have a product design that solves a primary problem for your customer, then you’re ready to make your idea a marketable product. Industrial designers focus on how to design and manufacture a product to solve the problem, and fit the market while staying true to the brand.Strong visual branding is the logical next design step to designing for your target market, so that it grabs their unique attention. To do so, you must ask: Who is this product for? Why are they using my product? Where are they using my product? This makes it a lot easier to find an aesthetic style that aligns with both your target user and your values as a company/individual. For example, designing sports equipment for children versus designing sports equipment for adults are completely different areas of design, each requiring specific design considerations. Good branding makes marketing the product more effective, as company marketing campaigns are generally more cohesive when the product is clearly visually aligned with the brand. 

Packaging can even influence the luxury and feel of a product. The marketing of water packaging targets specific demographics through material, graphics and marketing media. Evian uses soft pastels, flowing typography, and imagery of the French Alps which feels premium, fresh, and European. Mount Franklin uses clean whites, blues, and simple fonts that feels accessible, every day, and Australian. Voss uses a minimalist glass cylindrical bottle and a monochrome logo creating a high-end, modern and luxurious feel.

How we apply branding at Dienamics

How Industrial designers understand your brand and apply design language 

• We work to understand your audience: by understanding who your customers are or the target market you aim to design for, we can better determine visual ways to design your product so it resonates with your audience. 
• We work to understand you : by looking into the narrative behind your brand, whether that’s getting to know you, discovering your website or looking at some of your other products, we want to understand your product & company’s unique identity 
• We research the market: We cross check the market and the competitive landscape your product will be entering. This also helps to design new ways and develop ideas on how your product can differentiate itself from the other products on the market
• We explore visual identity and the overall aesthetic: 
  • By positioning your logo on prominent touchpoints, ensuring it’s at the forefront of the design 
  • Selecting a colour scheme is very important for reflecting the brand and aligning with other factors, such as drawing desired emotions and the certain user group. For example, bright playful colours appeal to children.
  • Typography if required for instructional labelling, information or company names, should be a font that suits your brands style 
  • Materials and finishes are important to convey feel and tone when the user interacts with the product. Examples include fluid lines that travel along parts, curved and soft edges to comfortably hold, we can do texture changes that can visually show logos 

Serve Neat’s Serving Platter is a clean and modern design that utilised subtle branding with a surface finish logo on the tray. We create a texture change by polishing the shape of your logo for a clean, seamless logo application. This often offers a sleek, subtle graphic placement that ensures your product can be traced back to your brand, without detracting from its overall look and feel.

Conclusion

In essence, branding guides the product development, it reinforces the brand’s identity visually. As designers, branding guides our process, we’re always thinking of new ideas to improve the design and shape how people perceive your product.  For businesses exploring how to design a new product, the key is to combine research, creativity, and branding into every stage of development.

If you’re interested in a more in depth blog on ways to incorporate branding into your product, see our blog on branding methods here.

At Dienamics, our award-winning team offers a range of comprehensive services in every step of the product manufacturing process. These include:

• Product design, including concept assessment and project scoping
• Prototyping and process and materials testing
• Manufacturing, injection moulding, production, assembly, and packaging

Contact us today if you have a product you’re looking to get designed and manufactured!

The post The Brand: Your Name, Your Face, Your Anchor, Your Language appeared first on Dienamics.

Transitioning your design from prototype to final product is a very exciting step in the product design process. When taking advice from industrial designers and injection moulding toolmakers, it is important to understand the benefits and implications of each tooling method. This will help you make informed decisions that affect the appearance, cost, and fabrication of the final product.

New to injection moulding? Read this article as an introduction to injection moulding, and this article to learn more about Cold Runner Systems.

Determining Factors

When creating an injection moulding tool for your product, there are a few key factors that will determine the tool most suitable for your design:

• Production volume requirements.
• Budget (initial vs long-term investment).
• Part features and moulding control.
• Assembly requirements.

One major tool design choice that impacts all these factors is the number of cavities in your tool.

Tooling Configurations Overview

Tooling configurations can be categorised into 3 main configurations:

• Single Cavity Tool – tool produces one part per cycle.
• Multi-Cavity Tool – tool produces multiple identical parts per cycle.
• Family Tool – a type of multi-cavity tool producing multiple different parts per cycle.

Let’s take a closer look at each of these configurations.

Single-Cavity Tools

First, single-cavity tools produce one part per run in an injection moulding machine.

Simplified single-cavity tool diagram (in a cold-runner system)

Single-cavity tooling ultimately creates the most precise and controlled moulding process with lower-volume production. The simplicity of these tools makes them easier to maintain and troubleshoot during moulding. Moulders can optimise machine parameters to ensure the part can be produced as accurately as possible creating a more controlled run and troubleshooting process. Whereas in a multi-cavity tool, adjusting settings to perfect one part can easily create defects in the other parts. 

It also offers the lowest upfront tooling cost as there’s only one cavity and the tool is as small as it can possibly be. However, the slower the rate of production means a higher the per-part production cost. So, while the initial cost of tooling is reduced, depending on the volume requirements of that part, when you factor in moulding costs, a single-cavity tool can result in a larger overall cost in the long run than with other tooling configurations. Therefore, for larger-volume production requirements, a multi-cavity tool should be considered to increase efficiency and reduce costs down the line.

Multi-Cavity Tools

Multi-cavity tools produce multiple identical parts in one cycle. 

Simplified multi-cavity tool diagram

CAD screenshot of a cold-runner multi-cavity tool. 

This configuration is the most effective for high-volume production, creating more products faster. 

Multi-cavity tools, unlike single-cavity tools, have a higher upfront tooling cost making them more suitable for high-volume production. By increasing the number of cavities in the tool, this increases the tool’s size and complexity which results in higher tooling costs to cover extra requirements for machining, additional steel and/or any required tool mechanisms such as lifters or sliders.

However, the more cavities result in lower per part prices. As the tool produces more parts per cycle (per shot of plastic), the cost per individual part is lower than what they’d be if moulded one by one in a single-cavity tool. Because of these per part cost savings, often the initial tooling investment is made back faster than with a single-cavity tool. This makes it appealing for those who can afford higher-cavity tools, or those with high volume requirements. 

The moulding result from a multi-cavity tool with a cold runner system, moulding multiple of the same part in one run. 

For clients requiring the production of multiple unique injection moulded parts, depending on volume, using individual steel moulds for each part may be too large of an investment. Thus, presenting the option for an alternative type of multi-cavity tool: family tools.

Family Tools

Family Tools produce multiple different parts in one cycle.

Simplified family tool diagram

CAD screenshot of a family tool

This configuration significantly reduces per-part production costs by manufacturing multiple parts in the same moulding cycle in the one tool and is suitable for low-medium volume production. Instead of investing in an individual tool for each part, the increased cost of building a family or multi-cavity tool is still often significantly lower than producing individual tools for each part. Typically, family tools are used to manufacture components that are part of the same assembly. However, they can also be utilised to mould parts belonging to entirely different products – this is discussed further below.

Key Considerations 

Sorting 

To reduce labour costs, the best tools are those that can be left to run on their own. 

For single and multi-cavity tools, the only sorting that is required is between parts, sprues and runners of a cold runner system. If the tool has a hot runner system, no sorting is required.

When a family tool is left running, all parts are ejected and collected in one container beneath the machine, resulting in a pile of unsorted products which will then need to be sorted by hand, or by costly automated machinery that are normally only set up for high volume mass manufacturing. The more difficult the parts are to sort, the more your labour costs will increase due to this labour and technical factor.

Therefore, if your design has similar parts, consider how the part’s interior or exterior appearance could be changed or adapted slightly to allow manufacturers to differentiate through parts with ease and reduce costs. Slight design adjustments also assist in the assembly process.

One of our talented Dienamics workshop staff, Valeria, separating parts from their sprues in our Brisbane workshop. 

Moulding Control Over Individual Parts

Moulding control refers to the amount of control an injection moulder has over the outcome of the part produced. For example, single cavity tools offer the best control in moulding as the machine settings and moulding conditions can be optimised to perfect the production of the individual part. This streamlines the troubleshooting and moulding process, allowing the moulder to identify problems and make small changes to machine parameters until the highest quality part is produced.  

Multi-cavity tools offer slightly less control to individual parts, due to the higher volume of parts. However, if the tool is balanced and has effective material flow and cooling, the uniformity of the parts typically allows them to mould effectively under the same conditions.

Moulding parts in family tools can be more difficult as each part must be run on the same settings (pressure, temperature, etc.). Due to variations in size and level of detail, the requirements to mould each part will vary. This creates a higher risk of defective parts if significant compromises are needed to be made to mould everything together. This is particularly an issue for tools that produce all parts needed for an assembly in one run. If one or more parts in that run are rejected, there can be an uneven number of approved parts produced. 

There are two main options to consider here:

• For parts that are likely to be lost in sorting or are more susceptible to defects, it’s a good idea to add an additional cavity of that part can be added to the family tool to prevent additional runs – this is most effective if the part is small or uses little material.
• Or runner blocks can be used to mould the temperamental part separately to the others on customised settings. This reduces material waste on parts that may otherwise consistently show defects when moulded with the rest of the tool. Let’s go into this a little bit further.

Runner Blocks

As briefly mentioned, runner blocks are used typically in family tools to stop the flow of plastic from accessing specific cavities in a family tool, allowing the manufacturer to mould parts on their own or exclude specific parts in a run. The moulder can then optimise the machine’s settings to suit the specific part/s being moulded and prevent the production of defective products created by the machining requirements for other parts.

As mentioned, they can also be used to mould separate parts in different materials and colours.

Runner blocks provide an effective solution; however, they add time to the moulding process and eliminate the benefits of moulding all parts together at scale in one moulding shot.

Injection

Cold runner systems on multi-cavity and family tools typically require longer runners than single-cavity tools. The runner and sprue are usually reground and mixed back in with the virgin material to be remoulded to reduce waste. However, if more than 20% of the material used in moulding is reground, there is a higher risk of producing parts with defects. Therefore, if the runner and sprue weigh more than 20% of the overall part weight, not all this material can be reground, increasing the amount of wasted material. To avoid this:

• Depending on the number of parts and requirements for material flow,  
  • Hot tips could be implemented directly into each cavity, using a hot manifold system to eliminate the sprue and runner entirely.
  • Or hot tips could be implemented into the runner to remove the need for a sprue

• Optimise balance with strategic cavity and gate placement to reduce runner weight.

To see if a hot manifold system is the best option for your tool: compare the higher initial tooling costs against the long-term savings from reduced material waste. 

For some more information check out our blogs on hot manifold systems and cold runner systems!

Material and Colour Changes 

In multi-cavity and family tools, runner blocks also allow different parts to be moulded in different materials or colours by selectively blocking cavities. Once the run of that colour or material is complete, the remaining material is then purged out to avoid contamination, colour speckling, and rejected parts. This process is then repeated as many times as required, closing off the unwanted cavities and running the new material or colour. However, moulding costs are increased due to the increased complexity in the process.

One of the amazing products we mould in our Brisbane workshop – Pendulum PMU makeup pencil sharpener – is a family tool we mould in two colours! The window/ clear part is moulded first to reduce risk of contamination. Then, after purging the remaining clear material, the part is runner blocked to mould the remaining parts in black.

Volume Implications for Family Tools

Similarly to multi-cavity tools, the production of multiple parts at once increases the cycle time, slowing the production of each part. For clients requiring very high-volume production, a family tool may not produce the required volume fast enough and instead it may be best to use multiple multi-cavity tools to meet their required production needs. Again, this requires very high-volume production to make this option financially viable.

Communicating Tool Configurations

When preparing a design for tooling, a toolmaker will provide you with a tooling configuration – referring to the number of unique parts and the number of cavities for each part in the tool.

Reference the table below for an example of how your tooling configuration name may look depending on how many unique parts you have, how many parts will be produced total per run, and as a result what type of tool you are running. This isn’t an exhaustive list; any combination of parts & cavities can exist across Multi-Cavity and Family Tools.

Summary

Single Cavity Tool

• Best for low-medium volume production of a single part
• Lowest initial tooling price with higher per-part cost

Multi-Cavity Tool

• Best for high volume production of a single part design.
• Higher initial tooling price with lowest per-part cost

Family Tool

• Best for low-medium volume production of multiple different parts
• Lower initial tooling price per-part with lower per-part cost 

Conclusion 

Referencing this information before taking your design to tooling and injection moulding justifies the manufacturing suggestions made by a toolmaker or designer, and ensures that the processes, outcomes and implications match your expectations for your product.

Thinking that injection moulding might not be the right fit? Read this article about other plastic manufacturing methods!

At Dienamics, we offer a range of comprehensive services in every step of the product manufacturing process. These include: 

• Product design, including concept assessment and project scoping 
• Prototyping and process and materials testing 
• Manufacturing, injection moulding, production, assembly, and packaging 

 Contact us today if you have a product you’re looking to get designed & manufactured!

The post Which Injection Moulding Tool Configuration Is Best for Your Product Design? appeared first on Dienamics.

Overmoulding has had a great impact on many key industries, and perhaps no field has benefitted more than the tech industry. Electronic devices are as durable and capable as ever, thanks to overmoulding. Read on to learn why this is, and how you can apply key features of overmoulding to your designs.

If you haven’t read Part 1, read it first here, or read this article on injection moulding if you are new to injection moulding.

Logitech & UE’s speaker range are outstanding exemplars of overmoulding.

Overmoulding and Cost Considerations

But first, in product design it’s always important to understand how our design decisions can affect cost and the environment.

Increased Costs – Overmoulding adds significant cost to the initial purchase of moulding tooling as it requires making a second mould. It also increases per part price as the base part needs to be injection moulded again through the overmoulding tool. This process adds another few steps to the manufacturing process. If there are any issues with the overmoulding of this part, it often means the entire part is now a reject, including the base part even though it may have been perfect. This increased potential for a higher reject rate further increases the per part price.

Knowing this, you can see why overmoulding is used sparingly and only in certain cases. You will rarely see it used “just because”, or purely for aesthetic reasons. In fact, at the time of writing this, I can’t think of or find a single example of using overmoulding purely for an aesthetic design goal – if you have an example please share this with me!

In almost all cases, overmoulding is used for a functional reason. Whether this be to provide manual grip, increase durability, increase surface friction, or proofing from shock, dust, and water. If the increased functional value added by overmoulding justifies the increased initial tooling and ongoing per part costs, then designers can take the opportunity to explore how they can leverage the overmoulding to enhance the products’ aesthetics.

Harder to Recycle – As overmoulding creates a strong, near-inseparable bond between two different grades of plastic, recycling these products is much less efficient. On the flip side, a well-designed overmoulded product is often more durable and lives longer than a non-overmoulded product and recycled plastics can be used, reducing the amount of raw material used as a whole.

This 2K mould here allows for multiple cores for each part, injecting the base part in yellow in a hard plastic (likely PC , ABS, or Nylon), and a soft plastic in black (likely a TPE or TPU).

Creating More Robust Electronic Devices

Overmoulding is a staple manufacturing process for the electronic tech industry, especially in devices designed for rugged, outdoor, and mobile use. Once you can identify it, you’ll see it everywhere.

Below is an overview on how it’s applied to achieve different functional goals. Also, the Logitech UE Boom speaker is a profound exemplar in overmoulding, so I’ll be referring to this a fair bit.

Water and Dirt-Tight Seals For Openable Assemblies – When assemblies need to have a certain proofness, often a separate seal O-ring is placed between assembled parts. Sometimes it’s more suitable to overmould a soft plastic in this space instead, overmoulding a soft plastic like TPE onto one of the parts. This can be less prone to failure than a separate O-ring, easier to assemble, and reduces the chance of human error during assembly.

Logitech uses soft plastic overmoulding throughout its UE Boom to achieve its waterproofness in its UE Boom speaker designs. The design is an assembly with multiple sub-assemblies and parts, including both end caps and the speaker membranes. Each of these parts sit against a soft plastic seal that is overmoulded onto the base part.

Enclosing Spaces In Permanently-Closed Assemblies – Overmoulding can be used to completely encase a part to entirely seal the internal area from water ingress. This is commonly used in devices that need to perform in extremely harsh environments or achieve high IP ratings such as IPX7 or IPX8.

The Safety Shovel we designed here in Brisbane, Australia uses this to completely protect its internal components from ingress in extremely harsh environments.

The Safety Shovel Head incorporates overmoulding to protect vital internal electronics.

Allowing Waterproof Access to PCB Buttons – Flexible soft plastic overmoulding can also offer a waterproof membrane between internal PCB buttons and external user buttons. Here, in the second injection moulding shot the soft plastic is overmoulded directly over the windows in the hard plastic that was made in the first injection moulding shot. These holes align with PCB buttons below, which can now be activated through the flexible soft plastic.

Both the UE Boom product design and the Elexon Biomark Housing that we injection mould in-house here in Brisbane use this technique to allow a soft touch outer to press PCB buttons.

Here, this piece uses overmoulding to protect from ingress, whilst allowing for PCB buttons to be activated by pressing on the soft plastic overmould that is injection moulded over the base clear polycarbonate part.

Acoustic Sealing for Speaker Design – Similarly, high-quality portable speakers often use overmoulding to create a perfectly sealed-off internal cavity that serves to better resonate sound waves of their passive bass radiator speakers. This produces a deceptively rich sound from such a small device. Again, UE Boom has used their same seals for not only proofing, but acoustic sealing as well.

Drop and Shock-Protection – Overmoulding a soft polymer over a product to cover any exposed edges or corners goes a long way to reduce the shock experienced by the internal electronics and hard plastic in the event of a bump or drop. Many soft rubberised plastic grades are also resistant to tearing and scratches, so wear on these parts looks better than scratches on a hard plastic surface.

You’ll often see this used on phone cases or devices made for hard-hitting outdoor use like handheld GPS devices or walkie-talkies. Many devices meant for mining also employ an overmoulded outer.

You don’t see this as often, but soft plastics can also be used internally to hold electrical components like PCBs and batteries securely away from the hard plastic walls of the device. This further dampens the shock transferred from the outside of the device to the electrical component.

The DEWALT DXFRS800 2-Watt Heavy Duty Walkie-Talkie incorporates its overmould to not only improve grip and shock protection, but also to encase its antennae and protect them from ingress.

Improved Manual Grip – This often goes hand in hand with shock protection and improved surface friction, though not always. You’ll see overmoulding used for grip more than any other use. From power tools to walkie-talkies, phone cases, gaming controllers, keyboards, computer mouses, and more. Soft-touch electronics have been around for a long time and seem to be here to stay. That said, there is a trend back towards mono-material products for their minimalistic look.

Most laser levels on the market now incorporate TPE or TPU overmoulding to improve surface friction, manual grip, and shock protection. (Source: Bob Vila)

Improved Surface Friction – You don’t often see products using overmoulding purely for improving surface friction or slip protection. Usually, these parts are separate parts (think feet or table legs), or the main reason for overmoulding is another of the points above, and improved slip protection is a side benefit.

Common Industries That Use Over-Moulding

Although you would be hard-pressed to find an industry that doesn’t use over-moulding in some form in their industrial design decisions, over-moulding has become industry standard and a hallmark for some select industries.

The Medical Industry – These are used commonly in various handheld devices to completely seal off internal components so that products can be sterilised thoroughly without fear of internal damage. Medical implants also use overmoulding to completely protect internal cavities.

Power Tools – Power tools almost all now leverage the shock-absorption and grip-adding properties of soft plastic overmoulding

Mining Industry – As mentioned above, the mining industry commonly use overmoulding for shock absorption, grip, and dust and water protection.

Consumer Electronics – You’ll start noticing evidence of overmoulding everywhere. Even looking down at my keyboard and mouse now I realise that they both use overmoulding in their grip areas.

Many ultrasound devices use overmoulding in the scanning area, to provide a secure seal to prevent any moisture ingress from ultrasound gel.

Keen To Learn More?

Inspired to learn more on injection moulding, industrial design, and toolmaking? Read more of our blog articles here.

At Dienamics, we offer a range of comprehensive services in every step of the product manufacturing process. These include:

• Product design, including concept assessment and project scoping
• Prototyping and process and materials testing
• Manufacturing, injection moulding, production, assembly, and packaging

Contact us today if you have a product you’re looking to get designed & manufacture!

The post Why Great Product Designs Use Injection Moulding Overmoulding – Part 2. appeared first on Dienamics.

Have you ever used a product and felt that it was pleasing to use and exuded high quality, but you couldn’t quite figure out why? Often subtle features in a product’s design will set them a cut above the rest. Sometimes it doesn’t take much: a subtle curve here and there, a textured finish, or simply weight in the right place. Another subtle injection moulding feature where industrial designers can make a massive difference is in overmoulding.

Keep reading to find out how you can use overmoulding in your product design to sit a notch above the rest so that your product is the first that customers reach for.  For a more technical and in-depth overmoulding article, see “What is Overmoulding? An Overview and Guide” or read this article on injection moulding first if you are new to injection moulding.

Power Drills are perhaps the most common application of overmoulding. Hilti are exemplars in high quality injection moulding and overmoulding – check out that texturing on the grip on the Sf 4h-22 Cordless Hammer Drill Driver!

What Is Overmoulding? A Brief Overview

Overmoulding — also known as overmolding or co-molding — is a plastic injection moulding technique that allows different plastic materials to be applied to the product in the same injection moulding process, without the need for assembly. The second material can either partially or fully encapsulate the primary material (also called the substrate).

It is used in a wide variety of industries and applications and is commonly visited in product development. The reasons for using overmoulding vary greatly and its applications are endless, including increasing grip, sealing products, shock protection, and improving a product’s look and feel. These applications are endless, provide extra value to your product, and can reduce assembly costs if the injection moulding company is fitted with robots to place the substrate into the injection moulding machine automatically.

While many materials can be used for plastic overmolding, the main combinations are:

• A soft plastic over a hard plastic – Often for grip, aesthetics, and waterproofing
• A hard plastic over a hard plastic – Often for increased protection, strength, and durability, or concealing and waterproofing electronics
• A hard plastic over a soft plastic/foam – For higher strength-to-weight qualities
• A soft/hard plastic over metal – Often to incorporate fixings, metal threads, or sensors.

Using Over-Moulding To Improve How Your Product Works

The possible applications for over-moulding are vast and always increasing — it simply depends on the industrial designer’s creativity, and the injection moulder’s ability.

Improving Grip – Perhaps the most used application of overmoulding, a soft rubberised plastic such as a TPE or TPU is over-moulded over various hard plastics like ABS in order to increase grip. Think of toothbrushes, power drills, steering wheels, or grips on computer mouses. The Hilti Drill shown at the start of the article is a perfect example of overmoulding for grip – zoom in and check out the diamond-hatch texturing on the grip. A work of art!

Incorporating Flexible Areas – Sometimes soft plastics are moulded over rigid components, to offer flexible sections for various applications. Examples include soft-headed kitchen utensils and shower suction cups.

The Dreamfarm Set of Essentials —designed here in Brisbane by their fantastic team of in-house industrial designers —is a great example of overmoulding to create a flexible surface. They’ve even taken the opportunity to use the soft coloured plastic into the eye loop for visual appeal.

Inserted Fixings and 3D-Printed Parts – Fixings can be overmoulded securely in place in a product, allowing for strong fixings which are commonly metal threads inserts, magnets, threaded rods, or other metal fixings. Less commonly, custom 3D-printed parts can be overmoulded, which offers the ability for 3D printed parts to be changed over time as needed, with the rest of the mould remaining the same.

Here, threaded inserts are overmoulded in place when injection moulding, to create strong fixing points for installation/assembly applications.

Inserted Circuitry – Sensors, circuit-boards, and cables can be overmoulded to be embedded in products to have sensors in places where would otherwise be impossible.  More on this in our next article on overmoulding in plastic injection moulding.

Most PVC electrical cables are overmoulded, placed by hand into a vertical injection moulding unit. This is a very secure and water-resistant method to attach cable ends to the rest of the cable.

Hygienic Sealed Products – Medical products and electrical medical implants can be completely overmoulded to seal off internal circuitry.

Elevating Your Product Design’s Look & Feel

Overmoulding isn’t just useful for how your product is used, but also in how it looks and feels. It is a strong opportunity for compelling product design.

Soft Texture to Touch – An otherwise simple product’s appeal can be elevated by simply using a soft plastic overlay to provide a different look and feel. The overmould can be applied in varying textures and shapes by the product designer to reflect the brand and desired aesthetic. Silicone rubber is renowned for being pleasing to touch, though modern TPEs and TPUs can perform just as well in most cases and are much easier to injection mould.

The Laserforce Gen8 Phaser & Chestpack both use overmoulded TPE – whilst on the Phaser it is primarily used for improving grip, the look is continued throughout the parts to provide a compelling aesthetic by its contrast with the diffused lighting.

Adding Graphics To Make Branding Pop – Different graphics and patterns can be displayed using overmoulded plastics, or to accentuate a brand’s logo placement. Normally, this is only done when the overmoulding process is already being used for another purpose in the product’s design, as employing overmoulding can be expensive due to the need in most cases of a second injection moulding tool.

Many water bottles – including this Nike bottle above – use overmoulding for their grips, but their industrial designers also take the opportunity to shape these for aesthetic appeal. Note that the Nike tick here is made via a window in the overmoulding, which is a very durable way of ensuring your branding is never rubbed off – which can happen when pad-printing.

Conclusion

Tune in next time to “Why the Best Product Designs Use Overmoulding, and Why Yours Should Too – Part 2”, to learn about how overmoulding creates more robust electronic devices, which industries most suit over-moulding, and financial and environmental costs of overmoulding.

If you’re interested in other ways to incorporate branding into your product rather than overmoulding, see our blog on branding methods here.

At Dienamics, we offer a range of comprehensive services in every step of the product manufacturing process. These include:

• Product design, including concept assessment and project scoping
• Prototyping and process and materials testing
• Manufacturing, injection moulding, production, assembly, and packaging

Contact us today if you have a product you’re looking to get designed & manufactured!

The post Why Great Product Designs Use Injection Moulding Overmoulding – Part 1. appeared first on Dienamics.

Selecting a proficient toolmaker in Brisbane can dramatically influence the efficiency, quality, and success of your manufacturing projects. Whether your needs involve intricate component designs or large-scale production outputs, understanding how to choose the right toolmaker is crucial. This guide delves deep into what makes a toolmaker stand out and how to ensure you partner with the best in the business. I’ll walk you through what the role of a toolmaker is in this day and age, some key factors to keep in mind when choosing a toolmaker that is right for you, and some red flags to watch out for. 

What Is The Role of a Toolmaker in Brisbane?

Toolmaking is an essential process in manufacturing, involving the creation of tools that produce other products. This includes moulds for plastic injection, dies for stamping, and jigs and fixtures for machining. The precision and reliability of these tools are paramount as they directly impact the production process and the quality of the final products. 

Brisbane and Australia’s number of toolmakers has dwindled significantly over the past few decades, with the offshoring of local automotive and whitegoods manufacturing, and those that have remained have found a niche and really developed their skills in this niche to stamp their presence as producers of high quality tools. Although many of these local toolmakers create tools themselves, many also partner with offshore toolmakers to meet the budgetary demands of certain projects. In these cases, the local toolmaker’s role is vital in ensuring the quality of the tool design and – if the tool is then imported – the ongoing maintenance, repair, and modifications of the tool throughout its working life. 

While toolmaking is a highly skilled profession, as in any industry it is possible to fall into the wrong hands. Toolmaking is no cheap business, so if you do fall into the wrong hands then it can be very costly. Let’s explore at what to look out for.

What Do I Need To Look For When Choosing a Toolmaker in Brisbane?

Moulding and Production Capabilities

Having a toolmaker with in-house moulding and production capabilities is immensely beneficial. Such toolmakers possess a comprehensive understanding of the entire manufacturing process, from tool design to final product creation. This expertise is particularly valuable because it allows the toolmaker to anticipate potential production challenges and adjust tool designs proactively to avoid them. Their direct experience in moulding provides critical insights that enhance the functionality and reliability of the tools they create. This deep understanding ensures that the tools are not only well-crafted but also optimized for actual production conditions, leading to higher quality products and more efficient manufacturing cycles. By integrating toolmaking with moulding expertise, these professionals offer a significant advantage in achieving seamless and successful production outcomes.

Local Expertise and Post-Production Support

Local expertise is essential when tools are made in Australia or shipped to Australia. A locally-based toolmaker is invaluable, as they are available to physically review and run the tool, ensuring its optimal performance from the start. This proximity allows them to perform ongoing repairs and maintenance, which is crucial throughout the tool’s lifetime.

Whether you are running your tools and moulding machines in-house, or if you’re outsourcing to a manufacturer like Dienamics, the availability of local support for maintenance, modifications, and repairs is vital. It’s important to confirm that the toolmaker offers comprehensive post-production support, including routine maintenance and emergency repairs. This support not only improves the functionality and longevity of the tools but also ensures that any issues can be swiftly addressed, reducing operational disruptions and maintaining production efficiency.

Quality Assurance

Quality assurance is integral to successful toolmaking. A reputable toolmaker in Brisbane will demonstrate a stringent quality control process that ensures each tool meets or exceeds industry standards.

A quality toolmaker will ask many questions of your product, the material you’re using, its requirements, environment of use, and target user before providing you with any quotes and absolutely before doing any tooling work. This is because producing a quality tool requires a deep understanding of the product and its critical requirements. 

Making a tool is not simple, so often toolmakers employ a “tool-first” methodology, where they make assumptions of the part/product to make the toolmaking as simple as possible, without truly understanding the needs of the product – or of you! Whilst this can result in a cheaper tool, it can also result in parts that have a host of problems that affect your supply chain, your credibility, your product performance, and your business. 

The kind of toolmaker that produces quality parts will employ a “product-first” methodology, where they will take the time to understand all the critical requirements of the product before looking at tool design. Then, they’ll seek to make the simplest and most robust tool that will meet the product’s exact needs. 

Customisation Abilities & Design Capabilities

Customisation is key in toolmaking to meet specific project requirements. Your chosen toolmaker should be flexible and skilled in creating bespoke solutions that integrate seamlessly with your manufacturing processes. This is where toolmaking and design overlaps. Sometimes, your product in its current state simply cannot be injection moulded either to your target per part price, or sometimes not at all. A skilled toolmaker will actually be able to redesign your part to meet all your requirements and also a per part price and feasible tool. 

• Custom Solutions: Discuss how the toolmaker has approached unique challenges and tailored solutions in the past.
• Innovative thinking: Have the proven track record to be able to apply design thinking and problem solving to your product and the tool.
• Industrial/Product Designers: The best toolmaking business in Brisbane and further afield have a team of industrial designers and engineers at their disposal, ready to tackle any design issues that may arise, and provide precisely controlled CAD data to the toolmaking team. 

Although this part may look simple to most people, to create this with an injection mould in a way that has a low part cost with a healthy profit margin requires some innovative tooling. We worked hard to realise Baby Bot Bot’s dream, using some innovative design and toolmaking to make it a reality.

Expertise and Experience

The expertise of a toolmaker is often evidenced by their longevity and the diversity of projects they have completed. When searching for a toolmaker in Brisbane, it’s important to consider their industry reputation and the breadth of their experience.

• Assessing Experience: Look for a toolmaker with a robust portfolio and seek examples of similar work they have done in the past. The applications of injection moulding are vast, and the requirements for each application are highly specific due to the complex nature of injection moulding and the balance of experience required in materials, moulding methods, tooling possibilities, and product design. Experience in your specific industry or with projects like yours can be highly beneficial.

Designing for The Better Brand’s Cosmetic range required us bringing together our wide expertise across manufacturing methods, using blow moulding, injection moulding, and aluminium extrusions to bring their product range together.

Ensuring Export Quality of Overseas Tools

Even if your toolmaker is outsourcing the initial toolmaking work overseas, a locally based toolmaker, whether in Brisbane or elsewhere in Australia, is important in understanding your intent, your needs and wants, and ensuring that the tool is made to these specifications. 

They will confirm they meet the necessary export standards to ensure compatibility and compliance with international quality and safety regulations.

• Verification of Export Status: Double-check the export suitability of any overseas-manufactured tools to avoid future operational and ownership challenges. We’ve had many customers come to us after buying a “cheap tool”, only to find that they don’t actually own the tool, and that the tool needs to remain overseas and used for manufacturing only by that toolmaker and manufacturer. Ensure that you own the tool and can do with it as you please.
• A quality toolmaker and manufacturer will also have long-term trusted suppliers, with agreements and processes in place to stop product copying. 

Potential Red Flags

Rushing the Quoting Process 

• If a toolmaker rushes through the quoting process without asking questions and thoroughly understanding your project requirements, they may overlook critical details that could affect the quality and cost of the finished product.

Unusually Low Prices

• While competitive pricing is attractive, prices that seem too good to be true can often indicate poor quality materials, shortcuts in the production process, non-tool ownership, or hidden costs that will emerge later.

Aren’t transparent with their processes or tool specifications

• Toolmakers should be willing to discuss their methods and the materials they use. A reluctance to provide detailed information about their processes can be a sign of cutting corners or lack of adherence to quality standards.

Insufficient Communication

• Poor communication is a significant red flag. If a toolmaker does not respond promptly to inquiries or fails to effectively communicate during initial discussions, it may reflect their overall approach to customer service and project management.

Limited or No References

• Reputable toolmakers should be able to provide references or testimonials from previous clients. A lack of references or unwillingness to provide them can indicate a lack of experience or unsatisfied customers.

Inflexibility to Adjust or Customise

• If a toolmaker is unable or unwilling to adapt to your specific needs or make adjustments as required, it may signal a rigid and potentially unsuitable service. Customisation capabilities are essential for many projects, and a lack of flexibility can result in a product that does not meet your specifications.

Conclusion

Choosing the right toolmaker in Brisbane or further afield requires a thorough understanding of their capabilities, technology, and the quality of service they offer. By focusing on these detailed aspects and conducting a comprehensive evaluation, you can ensure that you partner with a toolmaker who will significantly contribute to the success of your manufacturing projects, enhancing both product quality and operational efficiency.

We at Dienamics have over 30 years of experience in toolmaking, injection moulding, and design. Working at a high level across each discipline, we’ve worked with other toolmakers, moulders, and designers, and so we have an acute understanding of how each discipline works together, and also of the possible pitfalls that lie out there in the industry that can trap honest people trying to make good products. If you want an end-to-end service, expert advice, high quality tools, products, and product design that will help you realise your vision, then get in touch.

The post Choosing the Right Toolmaker in Brisbane: A Comprehensive Buyer’s Guide appeared first on Dienamics.

Selecting the right plastics manufacturing method for your project requires navigating a varied landscape of options, each with its unique benefits and challenges. This can be a daunting task. This guide aims to simplify that choice by providing a detailed comparison of popular plastics manufacturing techniques. From injection moulding and blow moulding to advanced 3D printing methods, we’ll explore what each process offers. This information is crucial for anyone looking to make informed decisions at any stage of product development, ensuring your design not only takes shape but does so in the most efficient and effective way possible.

Injection Moulding

Injection moulding involves melting plastic pellets and injecting the molten plastic into a mould under high pressure. It’s ideal for mass-producing high-precision, high-quality parts with a consistent finish, valued for its efficiency and precision. While it offers high-volume production with consistent quality, the upfront costs for mould design and manufacturing can be significant, making it less suitable for small runs.

Pros:

• High Efficiency: Once the mould is created, production is fast and cost-effective, especially for large volumes.
• Precision: Capable of producing complex shapes with tight tolerances.
• Material and Colour Flexibility: Supports a wide range of materials and colours.

Cons:

• Upfront Costs: High initial investment for mould design and production.
• Design Restrictions: Not all part designs are suitable for injection moulding due to limitations in mould design, however with considered, innovative design and good material choices a wide variety of complexities are possible. When it comes to mass-manufacturing complex parts, injection moulding is the go.

Blow Moulding

Blow moulding shines in creating hollow plastic parts, such as bottles and containers. The process involves extruding a heated plastic tube, which is then inflated inside a mould. Its main advantage is the ability to produce uniform, thin-walled items economically, though the method is limited in the complexity of shapes it can produce.

Pros:

• Ideal for Hollow Parts: Perfect for creating bottles, containers, and other hollow shapes.
• Cost-Effective for High Volume: Economical for large production runs after initial setup costs.

Cons:

• Limited to Hollow Parts: Not suitable for solid objects.
• Initial Costs: Like injection moulding, the mould costs can be high.

Image courtesy of  APR Tanks

Rotational Moulding

In rotational moulding, plastic powder is placed inside a mould, which is then heated and rotated along two perpendicular axes. This coats the interior of the mould evenly, forming hollow parts. This method is perfect for large, hollow parts with uniform wall thickness, such as tanks. Rotational moulding allows for intricate shapes and sizes but has longer cycle times and is generally more costly per unit than other moulding processes.

Pros:

• Uniform Wall Thickness: Excellent for parts that require uniform wall thickness without internal stresses.
• Design Flexibility: Allows for complex shapes and sizes, including double-walled and internally ribbed structures.

Cons:

• Slower Production: Cycle times are longer compared to other methods.
• Material Limitations: Not all plastics are suitable for rotational moulding.

Thermoforming

Thermoforming involves heating a plastic sheet until pliable, then forming it over a mould using vacuum, pressure, or mechanical means. Thermoforming is widely used for packaging and non-critical parts. It’s quick and cost-effective for prototypes and has a short lead time. However, it struggles with consistency in wall thickness and is limited in the detail it can achieve. Sometimes thermoforming is used in conjunction with injection moulding, in a process call in-mould decorating. Keep your eyes out for a future blog on this topic.

Pros:

• Low-Cost Tooling: Moulds can be made from less expensive materials, reducing upfront costs.
• Rapid Prototyping: Quick and cost-effective for prototypes or small production runs.
• Material Efficiency: Excess material can be trimmed and recycled.

Cons:

• Thickness Variation: Wall thickness can be inconsistent, depending on the draw depth.
• Detail and Depth Limitations: Less capable of forming very deep or highly detailed parts.
• Material Waste: Excess material from the forming process may lead to higher waste.

Plastics Machining and Fabrication

Plastics machining and fabrication encompass a variety of processes used to shape, form, and assemble plastic parts. These methods, including CNC machining, drilling, turning, and milling, are subtractive processes that remove material from a plastic block or sheet to achieve the desired shape. Fabrication techniques may also involve welding, bonding, and assembling multiple pieces to create complex structures. Machining and fabrication offer custom shapes and sizes and a high degree of flexibility and precision but can lead to higher material waste and costs for large-scale production.

Pros:

• Precision and Flexibility: CNC machining offers high precision and the ability to produce complex shapes and fine details.
• No Moulds Required: Unlike injection moulding, machining does not require expensive moulds, making it cost-effective for prototypes and small to medium production runs.
• Wide Material Selection: Machining and fabrication can be performed on a vast array of plastics, allowing for a broad selection of material properties and applications.
• Quick Turnaround: Without the need for mould creation, the turnaround time from design to finished part can be relatively short.

Cons:

• Material Waste: Being subtractive processes, machining and fabrication can produce significant material waste compared to moulding techniques.
• Cost Per Part: For high-volume production, the cost per part can be higher than moulding methods due to the time-consuming nature of the machining process.
• Limitations on Part Size: The size of parts can be limited by the size of the machining equipment and the availability of suitable plastic blocks or sheets.

Vacuum Casting

Vacuum casting, also known as urethane casting or polyurethane casting, is a method used to create small to medium volumes of high-quality, precise replicas of a master model. The process involves creating a silicone mould around a master model (which can be produced via CNC machining, 3D printing, or another method) and then using a vacuum to draw liquid polyurethane resin into the mould. The vacuum helps to ensure that the resin fills the entire mould evenly and without air bubbles, resulting in highly accurate and detailed parts. It is particularly useful for validating designs, conducting market tests, or fulfilling requirements for small batches of end-use parts where the cost and time investment of traditional moulding methods are prohibitive.

Pros:

• High-Quality Replicas: Vacuum casting produces parts with excellent surface detail and fidelity to the original model.
• Fast Turnaround: The process is quicker than creating new moulds for injection moulding, making it ideal for short production runs and rapid prototyping.
• Versatility in Materials: A range of polyurethane resins are available, mimicking various plastics’ properties, including rigidity, flexibility, heat resistance, and more.
• Cost-Effective for Small Batches: It is a cost-effective solution for producing a small number of parts, as the silicone moulds are less expensive and faster to produce than metal moulds.

Cons:

• Limited Mould Life: Silicone moulds degrade over time and with use, typically yielding 20 to 25 casts before losing accuracy and detail.
• Not Suitable for Large Volume Production: Due to the limited life of silicone moulds and the labour-intensive casting process, vacuum casting is not cost-effective for large-scale production.
• Material Properties: While a wide range of resins are available, the mechanical properties of vacuum-casted parts may not match those produced by methods like injection moulding, particularly for long-term use or under stress.

FDM Printing (Fused Deposition Modelling)

FDM printing creates objects by extruding melted plastic filament in a layer-by-layer fashion. This subset of 3D printing is popular for prototyping and functional parts due to its versatility and ease of use. While it allows for complex designs and rapid iteration, the surface finish can be rough, and the material strength may not match that of parts made through traditional manufacturing.

Pros:

• Design Flexibility: Can produce complex geometries that are difficult or impossible with traditional methods.
• Rapid Prototyping: Allows for quick iteration of design ideas.

Cons:

• Surface Finish: Parts may require post-processing to achieve a smooth surface.
• Material Strength: Parts are generally less strong than those made with traditional manufacturing methods.

SLA Printing (Stereolithography)

SLA printing (Stereolithography) uses a laser to cure liquid resin into solid plastic in a layer-by-layer approach. This process is preferred for detailed prototypes and models requiring a smooth finish, but the range of materials is limited, and the process can be slower and more costly than other 3D printing methods. DLP 

Pros:

• High Detail and Finish: Capable of producing parts with fine details and a smooth surface right out of the machine.
• Precision: Ideal for applications requiring tight tolerances.

Cons:

• Material Limitations: Limited to photopolymer resin materials, which may not have the same properties as other plastics.
• Cost and Speed: Generally, more expensive, and slower than FDM printing for producing parts, making it less suitable for high-volume production.

SLS Printing (Selective Laser Sintering)

SLS printing uses a laser to sinter powdered material, binding it together to form a solid structure. SLS is ideal for functional prototypes and small-batch production, offering strong parts with complex geometries. Though it provides great design freedom and material options, the surface finish can be grainy, and the process requires significant post-processing.

Pros:

• Strong, Functional Parts: SLS parts are durable and can be used for functional applications.
• Design Freedom: Like SLA, it allows for the creation of complex designs, including moving parts and interlocking pieces without assembly.
• Material Options: Offers a range of materials, including nylon and other engineering plastics, providing various mechanical properties.

Cons:

• Surface Finish: While stronger, the surface finish of SLS parts can be rough and may require post-processing.
• Cost and Production Time: The cost of SLS printing and the time it takes to produce parts can be higher compared to other 3D printing methods, though generally lower than SLA for comparable parts.

Making the Decision

When choosing the right plastics manufacturing method for your project, consider the following factors:

• Volume: How many parts do you need? High-volume projects may benefit more from methods like injection moulding, whereas low-volume or prototype projects might be better suited to 3D printing or thermoforming.
• Complexity: What level of detail and complexity does your part require? 3D printing technologies like SLA and SLS are excellent for complex geometries that are challenging or impossible with traditional manufacturing.
• Customisation: Do each of your products require full customisation, or partial customisation? 3D printing enables the creation of custom parts through insert overmoulding, where a 3D-printed part is inserted into a mould and then encased in injected plastic, resulting in a cost-effective, customizable moulded part.
• Material Properties: Different manufacturing methods offer access to various materials. Consider the mechanical, thermal, and chemical properties you need for your application. Traditional plastics manufacturing methods such as moulding and machining have access to a wide range of materials compared to 3D printing which is limited.
• Cost: Initial setup costs (e.g., moulds for injection moulding) can be high, but per-part costs decrease significantly at scale. Conversely, 3D printing has lower setup costs but might not scale as cost-effectively.
• Finish and Aesthetics: Consider the desired appearance and finish of your final product. Some methods, like SLA printing, provide a high-quality finish off the machine, while others may require additional post-processing.
• Precision: How precise do you need your part to be? For many applications, vacuum forming, rotomoulding, or FDM printing are not precise enough. Here, injection moulding, SLS and SLA printing shine.

Conclusion

Choosing the right plastics manufacturing method requires a nuanced understanding of each process’s strengths and limitations. By considering your project’s specific needs—whether that’s the intricacy of design, material specifications, production volume, or budget constraints—you can make an informed decision that aligns with your goals. Remember, each project is unique, and the best approach often involves consulting with experienced professionals who can offer insights tailored to your project’s requirements. With over 25 years of design, tooling, and manufacturing experience, strategic decision making in design and manufacturing is ingrained in us. Get in touch, and together we can navigate the complexities of plastics manufacturing to bring your vision to life efficiently and effectively.

The post Choosing the Right Plastics Manufacturing Method for Your Product Design appeared first on Dienamics.

In a world where everyone’s attention is pulled in all directions, the details of product branding matter. Companies strive to make a lasting impression on the customer, driving brand awareness, familiarity, and a relationship between the company and the customer. One effective way to achieve this is through the incorporation of logos on their injection moulded parts which can be costly if laser etching, pad printing, or using labels. Branding methods that are used in the injection moulding tool save not only extra branding cost, but also offer better durability than other methods. When it comes to in-mould branding, three techniques stand out: embossing, debossing, and surface finish.

What is Embossing, Debossing, And Surface Finish?

Embossing and Debossing are often confused. Embossing is when the material is raised from the surface of the part, and debossing is when the material is lower than the surface of the part. How I personally distinguish the two is to think that “de”bossing is where the feature is “de”pressed into the surface. When embossing or debossing a logo on a product’s surface, the opposite or negative of that shape is made in the moulding tool.

ServeNeat’s Serving Platter incorporates both a raised embossed logo in the lid (left), and a surface finish-made logo on the base (right). Whilst the embossed logo is suited to clear materials with high refraction like PMMA & Polycarbonate, the surface finish logo on the tray is complimentary with only subtle branding.

As for using surface finish; quite simply you can adjust the surface texture of the part in the shape of your logo for a clean, seamless logo application on your product. This often offers a sleek, subtle brand/graphics placement that is great ensure your product can be traced back to your brand, without detracting from its overall look.

Why Emboss, Deboss, or Adjust Surface Texture?

Embossing, debossing, or texturing logos on your injection moulded parts offer numerous benefits. These methods provide durability, as the logo is moulded directly into the material, making it resistant to wear and tear and eliminating the risk of fading or peeling over time as opposed to other options like laser etching, pad printing, or using labels. In-mold logo options will result in a long-lasting representation of your brand.

How Much Is Too Much?

There is a common misconception that a logo must extend from the surface by at least 1mm or more in order to be noticeable. At times, we receive numerous suggestions regarding how far individuals want their logo to be recessed or protruded. To address this, we recommend laser etching for those seeking a subtle logo that seamlessly integrates with the product, or a minimal emboss or deboss of approximately 0.2mm. To provide a visual reference, we have prepared some examples demonstrating the ideal levels of logo extrusion or indentation. A logo depth of 0.1mm may be too subtle to catch attention, particularly if a different surface finish is not employed for your logo. On the other hand, a 0.2mm depth is generally considered optimal, as it allows the logo to stand out adequately without creating sharp corners or causing the part to stick during ejection. While a protrusion of 1mm is feasible, it increases the risk of ejection issues and may hinder the smooth removal of the part from the mould. As you can see, embossing and debossing more than 2mm is impractical and absurd. It is crucial to strike a balance between visual impact and functional considerations to ensure a successful integration of your logo onto the part.

Common Problems and Solutions

Logo/Branding Changes

Furthermore, logos frequently undergo changes or updates within a few years. Fortunately, there exists a simple solution to address these issues effectively: logo inserts. These inserts are blocks that can be easily replaced in and out of the tool. By placing the logo on an insert, any damage or necessary updates can be easily resolved by creating a new logo insert and replacing the existing one. This approach significantly reduces the need for replacing the entire tool, providing a cost-effective and efficient solution to maintain the integrity and longevity of your logo.

While embossing and debossing techniques are highly effective, they can sometimes result in the formation of witness lines—subtle marks or imperfections on the surface of the moulded part where the insert meets the tool. Fortunately, innovative toolmakers and designers have devised a clever solution. A border is often incorporated around the logo or text, effectively concealing these witness lines. By transforming the problem into a feature, it becomes possible to hide and avoid any visual inconsistencies.

Wear & Tear

Embossing and debossing can present certain challenges, particularly related to the wear and tear of intricate details. Given that logos often contain intricate elements, any signs of wear and tear, such as deformation of letters, can become noticeable. This is more present in embossed features, as the logo is raised from the surface and are often catching points for abrasion and scrapes. On the other hand, debossed features are protected from abrasions and can be more durable in the long run.

Importance of Surface Finish

Regardless of whether you choose embossing, debossing, or using a surface finish, a suitable surface finish for both the graphic feature and the surrounding surfaces is crucial. A smooth and consistent finish enhances the visual impact of your logo, ensuring it stands out prominently on the product. To make your logo stand out, it is customary to have a distinct surface finish for the logo compared to the rest of the part.

Ideally, the main surface of the product should have a slightly rougher texture (achieved through Electrical Discharge Machining), while the logo itself should be polished, or vice versa. When a logo is debossed, it is considerably easier to polish or roughen the tool/mould as it is raised from the rest of the tool (the opposite/negative of the debossed feature in the part). Alternatively, embossed logos are much harder to polish in the tool as now you’re polishing inside a small depression which makes access difficult.

This Land Cruiser Arm Rest we designed for Cruiser Consoles uses surface finish and contrast to great effect. It contrasts a polished embossed logo against the classic, EDM-machined texture to accentuate the logo, reflecting light differently to the surrounding surface of the part.

Alternative Branding Options

In scenarios where the wall of the part is close to vertical, embossing, debossing or surface texture may not be feasible as the tool is moving along an angled face. Here is when you would use other options such as laser etching, pad printing, or labels.  These options are applied to the part after it is moulded, so increases production cost where the in-mould options mainly increase tool cost. As a quick overview, laser-etching uses a laser to etch or engrave the desired shape into the product, pad printing using a printing press to apply a chemical imprint of your graphic to the product in whatever colour you want, and labels are what they sound like – printed labels that you then apply to the product as a sticker. There is also the option of in-mould labelling – where a label is set into the mould and the plastic is injected around this label – though you’ll find that the main tooling suppliers who provide this are dedicated manufacturers of containers and buckets.

Keep an eye out in future for a blog providing an in-depth overview of the various methods of applying a logo and graphics to your product.

Conclusion

When it comes to branding on injection moulded parts, embossing and debossing logos provide a distinct advantage, offering durability and consistent reproduction. By strategically designing around witness lines and exploring alternatives like laser etching, you can achieve impeccable results even on challenging surfaces. Remember that logo extrusion is not always necessary for a memorable impression, and a suitable surface finish adds that final touch of finesse. Choose the method that best suits your product and brand image, and let your logo leave a lasting impression in the minds of your customers.

If you’re up to the stage of putting your logo on your product, or you want to know about getting to that stage, why not book in for a free consultation to get your product design journey started?

At Dienamics, we offer a range of comprehensive services in every step of the product manufacturing process. These include: 

• Product design, including concept assessment and project scoping 
• Prototyping and process and materials testing 
• Manufacturing, injection moulding, production, assembly, and packaging 

 Contact us today if you have a product you’re looking to get designed & manufacture!

The post Elevate Your Brand: Injection-Moulded On-Product Branding Using Embossing, Debossing, or Surface Finish appeared first on Dienamics.