A CAD model may look perfect. But during molding, plastic behaves differently under cooling and shrinkage. That’s where sink marks and warpage begin. What is a sink mark? A visible depression on the surface caused by uneven material shrinkage.
Usually caused by:
• Thick sections
• Improper rib design
• Heavy bosses
• Non-uniform wall thickness
What is warpage?
Part deformation caused by uneven cooling and internal stress.
Result:
• Bent parts
• Poor fitment
• Gap & flush issues
• Assembly mismatch
Common beginner mistake:
Designing only for shape, without considering cooling behavior and material shrinkage.
What experienced engineers evaluate:
• Uniform wall thickness
• Rib-to-wall ratio
• Cooling consistency
• Material flow behavior
• Local mass concentration
• Structural balance during cooling
Important:
More material does not always mean stronger design. In plastics, excess material often creates defects.
Good engineering controls:
• Material distribution
• Cooling balance
• Shrinkage behavior
• Manufacturability
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Accurate CAD only delivers value when it reflects real manufacturing conditions.
Designs that consider machining, tooling, and production constraints early reduce rework, shorten cycles, and perform reliably on the shop floor.
#CAD#Manufacturing#DFM#MechanicalEngineering
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