From CAD to Production: How DeKALB Supports Design Optimization
A CAD file may look complete on screen, but production readiness is another story.
Geometry, material behavior, tooling strategy, and long-term performance all influence whether a part performs the way it was intended. In structural foam and gas assist molding, those considerations matter even more.
As a company, DeKALB is focused on accountability, collaboration, and getting it right. So is our approach to design optimization. Projects move more smoothly when engineering gets involved early; at DeKALB, those conversations happen before tooling construction begins, while changes are still manageable and cost-effective.
Engineering Input Before Tooling Begins
Some projects come in fully modeled and production-ready; others begin with performance requirements, legacy parts, or challenges that need to be solved.
In both cases, DeKALB’s engineering team evaluates the design with manufacturing in mind.
Key questions typically include:
- How will the material flow in structural foam or gas assist?
- Does the geometry support consistent molding conditions?
- Are part features aligned with the selected manufacturing process?
- Will the design support long-term dimensional stability?
- Does the overall strategy support stable production over time?
These discussions are designed to protect investment and avoid unnecessary risk. Adjusting a CAD model is simple – making changes after tooling is built is not.
Designing for Structural Foam
Structural foam molding behaves differently than traditional injection molding. The process creates a dense outer skin with a cellular core, increasing stiffness while reducing overall weight.
This structure opens up opportunities, but it also requires intentional design.
Structural foam parts typically run thicker than conventional injection molded components. That added thickness supports rigidity while still allowing weight reduction compared to solid plastic alternatives.
Structural foam also allows larger, more integrated components. In many cases, multiple parts can be combined into a single molded structure, reducing assembly labor and hardware.
For OEMs producing large industrial housings or structural components, these considerations directly affect durability, weight, and long-term cost control.
Designing for Gas Assist
Gas assist molding introduces pressurized gas into the molten plastic to hollow out thicker sections. When applied correctly, it reduces sink, lowers material usage, and improves structural consistency.
Successful gas assist applications require thoughtful planning to support consistent performance and surface quality. Process alignment during the CAD phase helps confirm that the design supports reliable production once the program moves forward.
Careful review early in development helps avoid complications later in tooling and sampling.
Tooling Strategy Is Part of the Design
Production volumes, part size, and performance expectations all influence how a program is planned. DeKALB evaluates those factors early to help align design intent with manufacturing realities.
Cycle stability, surface consistency, and repeatability depend on more than a single successful mold fill. They depend on integration between engineering, tooling, and operations. When those teams stay aligned, launches move faster and sampling tends to go more smoothly. DeKALB approaches projects from the start with this deliberate coordination.
From Prototype to Production
Design optimization does not stop once geometry is finalized.
Early sampling validates structural performance, fit, and assembly integration. Larger structural foam components also require evaluation of handling, machine capacity, and shot size.
Production readiness involves more than mold fill. It includes repeatability, safety, and process stability.
DeKALB’s team understands that success means delivering parts that perform consistently, not just once, but over the life of the program.
Reducing Risk Through Collaboration
Skipping design optimization rarely saves time. It often creates:
- Tool rework
- Cycle inefficiencies
- Cosmetic defects
- Structural concerns
- Assembly complications
DeKALB’s culture emphasizes integrity and follow-through. This mindset applies during engineering review as much as it does during production.
Our customer relationships are built on proactive communication and steady execution, especially during project launches. Engaging early in the design process strengthens that partnership.
Start the Conversation at the CAD Stage
Engineering collaboration during the CAD phase provides flexibility. It allows adjustments that improve manufacturability, structural performance, and long-term cost efficiency before major capital investment is locked in.
DeKALB Molded Plastics works alongside OEM engineering teams to evaluate geometry, material selection, and tooling strategy for structural foam and gas assist components.
If you are developing a large or complex molded part, connect with the DeKALB team early. An engineering review at the beginning of the process supports a smoother path from CAD to full production.