Plastic Product DFM Audit & Mass Production Readiness Consulting

This project focused on reviewing and optimizing an existing plastic product poorly designed for injection molding. The original design had manufacturability risks including unreasonable wall thickness, undercut interference, and moldability issues that would lead to high scrap rates and costly mold rework. I performed a full DFM audit, identified structural defects, provided detailed design improvements, and delivered a complete mass-production readiness report with recommendations to eliminate production risks and ensure the product is ready for volume manufacturing. Client product details are fully anonymized to protect confidentiality. All visuals show only design issues, recommendations, and before/after optimization logic, not the original product. All displayed designs are posted with clients’ permission. Five-star reviews are from my past finished projects.