Injection Molding DFM Review — ABS Plastic Enclosure

Performed a full DFM audit on a 2-part ABS injection molded enclosure, identifying and resolving 5 critical manufacturing issues before tooling commit. Issues resolved: - Non-uniform wall thickness (1–4mm) → 2.5mm uniform - Zero draft angle → 1.5° minimum on all walls - Sharp internal corners R0 → R2mm fillet - Unreinforced boss → 4× cross-rib added - Zero-draft cylindrical core → draft corrected Results: - Estimated $3,000–5,000 tooling cost saving - Cycle time reduced ~15% - Zero scrap risk from part sticking