Design for Manufacturing (DfM) using the OLLEIRA® Cutlery Basket as an Example – From Idea to Perfect Injection Molded Part

Introduction

When I started with the idea for my OLLEIRA® cutlery basket, one thing was immediately clear to me: If I wanted to make the product truly high-quality, durable, and innovative, I had to develop it injection molding-friendly from the very beginning. No copy-paste design, no quick fixes. Instead: a structured development process with a clear focus on Design for Manufacturing (DFM).

In this experience report, I'll show you how I used Fusion 360, Moldflow simulations, and a series of optimization loops to create a product that can be manufactured in series both functionally and economically perfectly.

What does DFM mean in injection molding?

Design for Manufacturing (DFM) means that a component is not only designed to look good or function, but also to be efficiently and flawlessly manufacturable. In plastic injection molding, the following factors play a role:

• Uniform wall thicknesses

• Sufficient draft angles

• Avoidance of undercuts (or targeted planning with side cores)

• Optimal gate and flow direction

• Control of pressure losses and weld lines

This is how I proceeded

1. CAD Modeling in Fusion 360

I modeled my product myself in Fusion 360 and focused from the beginning on:

• Draft angles

• Modular design (basket, handle, clip)

• Accuracy. I continuously checked the draft angles with 3DTool24.

2. Moldflow Analyses

To test and optimize manufacturability, I conducted Moldflow simulations. Here are some highlights:

• Wall thickness distribution: Even distribution with only minimal deviations at structurally necessary points.
  

• Draft angles: Mostly >3°, thus optimal for automatic demolding without additional mechanisms.
  

• Undercuts: Targeted areas with planned side cores – deliberately used for function.
  

• Weld lines: Avoided by clever gate positioning or shifted to harmless zones.
  

• Pressure distribution & injection pressure: Homogeneous flow direction, no hot spots.
  
  

• Fiber orientation: Optimal surface alignment for stability.
  

Conclusion: Why DFM pays off

Many startups leave the topic of DFM to the mold maker – and later wonder about warping, cracks, or unusable parts. I chose a different path:

• Planned from the beginning

• Simulated instead of guessed

• Structurally optimized

The result is a product that not only functions, but can also be produced efficiently, cost-effectively, and durably.

Your checklist for an injection molding-friendly design (DFM Basics)

1. Maintain uniform wall thicknesses

2. Plan draft angles >1.5°

3. Avoid undercuts or secure them

4. Plan Moldflow simulation early

5. Do not leave the mold maker alone with CAD problems

6. Consider flow direction, pressure, temperature

Interested in more insights?
Then feel free to sign up for my newsletter – there I regularly share exciting insights, tips on product development, and exclusive background information on the creation of the OLLEIRA® cutlery basket.

Why we go to this effort becomes clear when you look at the hidden costs of cheap cutlery baskets.”

Want to see what it turned into?
Then take a look at the OLLEIRA® Universal cutlery basket for dishwashers:

Claudio Pascariello – Owner & Developer of OLLEIRA® Household Products.