REBAN Product Design Tips
Core Principles for Rapid Prototyping
Function-First Methodology
Validation Hierarchy: Prioritize core functional validation (structural loads, assembly fit, and motion testing) over aesthetics during early phases.
Geometry Rationalization: Retain only the critical geometry required for functional verification to reduce toolpath complexity.
Modular Architecture: Split complex assemblies into testable sub-modules for phased validation, speeding up troubleshooting and iteration cycles.
Manufacturing Process Matrix
| Manufacturing Process | Best Applications | Key Materials | Standard Tolerance |
|---|---|---|---|
| CNC Machining | High-precision EV, Medical, and Aerospace structural parts. | AL6061/7075, Stainless Steel, Titanium, PEEK, Delrin. | ±0.01 to 0.05 mm |
| Injection Molding | High-volume production (1k+pcs) for consistent, durable parts. | ABS, PC, Nylon (GF), TPE/TPU, PP, High-performance Resins. | ±0.05 to 0.1 mm |
| Vacuum Casting | Bridge production (10-100 pcs) with production-like properties. | Polyurethane (PU) resins mimicking ABS, PC, or Rubber. | ± 0.15 to 0.3 mm |
| 3D Printing (SLA/DLP) | Highly detailed aesthetic prototypes, lenses, and master patterns. | Clear, Tough, High-temp, and Flexible Resins. | ±0.1 mm |
| Sheet Metal | Rugged electronics enclosures, chassis, and internal brackets. | Aluminum, Stainless Steel, SECC, Galvanized Steel. | ± 0.2 mm |
Design Optimization Techniques
Cost-Efficiency Strategies
1-10 pcs: 3D Printing or CNC Prototyping.
10-100 pcs: Urethane Casting or Rapid CNC.
500+ pcs: Bridge Injection Molding.
- Setup Reduction: Design parts with features accessible from fewer orientations (ideally a single setup) to drastically lower CNC labor costs.
- Standardization: Use standard drill sizes (metric/imperial) for holes and common radii for fillets to avoid the expense of custom tooling.
- Batch Scaling:
Structural & Wall Integrity
Wall Thickness:
Metals (Alu/Steel): Recommended ≥1.0 mm (Min 0.5 mm for small localized features).
Plastics (CNC/Molding): Recommended 1.5 mm – 3.0 mm.
Tip: Uniform wall thickness is critical to prevent warping and internal stress.
Deep Pockets: *Limit cavity depth to 4x the tool diameter to avoid tool deflection.
Apply a radius (R ≥ 1/3 of pocket depth) to all internal vertical corners to allow for high-speed CNC milling.
Assembly & Fastening
Threaded Inserts: For frequently disassembled medical/electronic housings, design for Brass Heat-Stake Inserts rather than tapped plastic.
Self-Centering: Incorporate 1°to 2° tapers on alignment pins to simplify robotic or manual assembly.
EMI Shielding: For electronic enclosures, ensure a 0.05 mm “gap-free” contact zone on mating flanges for conductive gasket compression.
Material & Finish Selection Guide
| Engineering Target | Recommended Materials | Critical Post-Processing | Key Industry |
|---|---|---|---|
| Biocompatibility | Titanium Grade 5, Stainless 316L, PEEK | Electropolishing, Citric Passivation | Medical / Surgical |
| Thermal Management | Aluminum 6061-T6, Pure Copper C1100 | Clear Anodizing, Alodine (Chromate) | EV / Power Systems |
| EMI / RFI Shielding | Aluminum Alloys, Nickel-Silver, ABS+PC | Conductive Paint, Electroless Nickel | Telecom / Electronics |
| Impact Resistance | Polycarbonate (PC), Nylon 12 (GF), TPU | Vapor Smoothing, UV-Hard Coating | Industrial Automation |
| High-Temp Stability | Ultem 1010, PEEK, Inconel 718 | Stress Relieving, Heat Treatment | Aerospace / Under-hood |
| Aesthetic Branding | 6-series Aluminum, PMMA (Acrylic) | Bead Blasting, Laser Etching, PVD | Beauty Tech / Consumer |