Injection-Molding Ready Flashlight Housing

Designed a two-part plastic flashlight housing in SolidWorks, built for injection-molding manufacturability from the start. Used a uniform ~2mm wall thickness, reinforcing ribs for stiffness, 1° draft angles for clean ejection, and fillets to reduce stress concentration and improve material flow. Addressed key DFM factors — parting direction, undercuts, gate accessibility, and boss/mounting design — and ran draft analysis on both halves to verify moldability before finalizing geometry. Locating pins were designed with minimal draft for secure, precise alignment between the two housing halves. Result: A functional two-piece housing balancing structural strength, material efficiency, and real-world moldability. Software: SolidWorks | Focus: Plastic Product Design • Injection Molding • DFM