Optimizing Design and Cutting Costs with DeKALB’s Engineering Services
Developing plastic parts for structural applications requires more than a good concept. Performance, manufacturability, and cost must all be addressed early and addressed together. DeKALB Molded Plastics takes an engineering-first approach to help customers bring stronger, more efficient designs to life.
From CAD modeling to mold flow analysis and tooling guidance, DeKALB provides targeted engineering support to reduce part count, improve part quality, and control costs from the outset. These services are backed by decades of experience in structural foam molding, where the right design decisions can make a significant impact.
Read on to see how early engineering involvement helps drive smarter, more cost-effective outcomes.
Built-In Engineering Support from Day One
Every project starts with a conversation. DeKALB’s team takes the time to understand how a part functions, how it fits into the larger assembly, and what constraints are in place, technical, budgetary, or otherwise. That understanding becomes the foundation for a collaborative development process.
Designs are reviewed for material flow, strength, and efficiency. Where possible, features are consolidated into a single molded piece, reducing fasteners and secondary operations. Complex assemblies often become simpler, stronger, and more cost-effective through this approach.
The goal isn’t to rework a design after it fails. It’s to refine it from the beginning so that production runs smoothly and consistently.
Using CAD and Finite Element Analysis (FEA) to Refine Designs
DeKALB engineers rely on CAD software not just for drawing geometry but for understanding how that geometry performs under pressure. FEA tools simulate stress and strain, highlighting potential weak points before a mold is ever built.
Adjustments to rib structure, wall thickness, or mounting features often emerge from these simulations. Instead of reacting to problems during prototype testing, our team works to avoid them altogether. That saves time and allows more attention to be focused on performance and cost-efficiency.
Mold Flow and Cooling Analysis for Better Process Control
Flow behavior inside the mold has a direct effect on part quality. DeKALB uses mold flow and cooling analysis to predict how resin will move through the tool, how it will pack out, and where defects are most likely to occur.
These studies inform critical decisions about gate placement, venting, and cooling channel design. When plastic fills uniformly and cools evenly, warping and shrinkage are minimized. That stability translates to fewer scrap parts, tighter tolerances, and shorter cycle times.
Reducing Costs Through Smarter Design Choices
Early engineering engagement allows us to suggest cost-saving improvements that don’t sacrifice performance. Structural foam molding is especially well suited for part consolidation and lightweighting, both of which lower total material and tooling costs.
For many applications, multiple metal or fiberglass components can be combined into a single molded part. The resulting product may be lighter, more durable, and easier to assemble. In some cases, tool design can also be simplified, further reducing upfront investment.
Our team evaluates trade-offs carefully. Every change is considered in the context of structural performance, manufacturability, and long-term efficiency.
Tooling and Material Expertise That Supports the Full Project
Tool design plays a major role in production outcomes. We work closely with customers and toolmakers to develop mold concepts that match the part’s geometry and processing needs.
Material selection receives similar attention. Thermoplastic alternatives to fiberglass or metal are evaluated not just for strength, but for dimensional stability, finish quality, and environmental performance. These materials often reduce waste, eliminate VOC concerns, and provide consistent results over large volumes.
Support doesn’t end once the mold is built. DeKALB remains involved through validation and production, helping customers fine-tune parameters and address new challenges as they arise.
Focused on Practical Results
Engineering at DeKALB is focused on outcomes. Every decision is aimed at producing a high-quality part that performs as expected, without inflating costs or timelines. Our team applies practical experience and analytical tools to help customers move from concept to production with clarity and control.
Structural foam molding has its own advantages, but those benefits only reach their full potential when design and process are aligned. That alignment starts with engineering support grounded in real-world application.
Let’s Talk About Your Next Project
Early involvement makes a difference. DeKALB’s engineering services are here to help you reduce complexity, avoid delays, and improve total project value.
Get in touch to learn how our team can support your product development goals.