Enclosure and injection mold design is similar to PCB design … it’s full of pitfalls and obstacles, and you learn by making mistakes. The difference between PCB design and design an injection mold, though, is unfortunately about $50 versus $5000 or more! Better to do some solid research before trying your first mold out! Some of the easier to avoid pitfalls (avoid sharp corners, ensure constant wall thickness, choosing the wall thickness based on the material being used, etc.) are described here in Plastics Part Design and Moldability. Have any experience (positive or negative) having molds made yourself or a pointer to good sources of information on mold design? Post them up in the comments!
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