--- title: Plastic Injection Molding DFM: Why Adding More Plastic... description: Uneven wall thickness in plastic injection-molded parts is a hidden but costly design flaw. Adding more plastic doesn't automatically improve strength — it can... canonical: https://daily.dev/posts/plastic-injection-molding-dfm-why-adding-more-plastic-can-make-a-part-worse-iwq8oemdo twitter:card: summary_large_image twitter:site: @dailydotdev og:type: website og:site_name: daily.dev og:title: Plastic Injection Molding DFM: Why Adding More Plastic Can Make a Part Worse | daily.dev og:description: Uneven wall thickness in plastic injection-molded parts is a hidden but costly design flaw. Adding more plastic doesn't automatically improve strength — it can... og:url: https://daily.dev/posts/plastic-injection-molding-dfm-why-adding-more-plastic-can-make-a-part-worse-iwq8oemdo og:image: https://api.daily.dev/og/posts/IWQ8OEMdO.png og:image:alt: Plastic Injection Molding DFM: Why Adding More Plastic Can Make a Part Worse og:image:width: 1200 og:image:height: 630 og:locale: en --- > ## Documentation Index > Fetch the complete documentation index at: https://daily.dev/llms.txt > Use this file to discover all available pages before exploring further. # Plastic Injection Molding DFM: Why Adding More Plastic Can Make a Part Worse **[Medium](https://daily.dev/sources/medium_js)** · 9 min read · 0 upvotes · 0 comments ## Summary Uneven wall thickness in plastic injection-molded parts is a hidden but costly design flaw. Adding more plastic doesn't automatically improve strength — it can cause sink marks, warpage, longer cooling cycles, dimensional variation, and assembly problems. The post explains how ribs, bosses, and thick wall transitions create localized heat and shrinkage issues, how gate location and cooling strategy amplify these problems, and what a proper Design for Manufacturability (DFM) review should cover before tooling is cut. It also outlines what information buyers should include in an injection molding RFQ to avoid expensive surprises. ## Full article daily.dev links to this article rather than hosting it. Read it at the original source: ## Similar posts on daily.dev - [Corners Lifting On 3D Prints? Guide Gives Prevention Tips](https://daily.dev/posts/corners-lifting-on-3d-prints-guide-gives-prevention-tips-tphwcjdh6) · Hackaday · 0 upvotes · 0 comments - [3d printed parts have different strength characteristics than conventionally-manufactured parts](https://daily.dev/posts/3d-printed-parts-have-different-strength-characteristics-than-conventionally-manufactured-parts-2kmtnp8jc) · Jacob Kaplan-Moss · 0 upvotes · 0 comments - [Your first 3D design will fail without knowing these 4 details](https://daily.dev/posts/your-first-3d-design-will-fail-without-knowing-these-4-details-17qzht6i3) · XDA Developers · 0 upvotes · 0 comments - [How to Avoid Higher Rigid-Flex PCB Prototyping Costs](https://daily.dev/posts/how-to-avoid-higher-rigid-flex-pcb-prototyping-costs-hqppyimrk) · Embedded.com · 0 upvotes · 0 comments - [I love functional prints, but I'd never trust my 3D printer with these 3 household fixes](https://daily.dev/posts/i-love-functional-prints-but-i-d-never-trust-my-3d-printer-with-these-3-household-fixes-pjsaoktfc) · XDA Developers · 0 upvotes · 0 comments --- Tags: [#manufacturing](https://daily.dev/tags/manufacturing) [View this post on daily.dev](https://daily.dev/posts/plastic-injection-molding-dfm-why-adding-more-plastic-can-make-a-part-worse-iwq8oemdo) ```json {"@context":"https://schema.org","@graph":[{"@type":"Organization","@id":"https://daily.dev/#organization","name":"daily.dev","url":"https://daily.dev","logo":{"@type":"ImageObject","url":"https://daily.dev/apple-touch-icon.png","width":180,"height":180},"sameAs":["https://twitter.com/dailydotdev","https://github.com/dailydotdev","https://www.linkedin.com/company/daily-dev-ltd"]},{"@type":"WebSite","@id":"https://daily.dev/#website","url":"https://daily.dev","name":"daily.dev","publisher":{"@id":"https://daily.dev/#organization"},"potentialAction":{"@type":"SearchAction","target":{"@type":"EntryPoint","urlTemplate":"https://daily.dev/search?q={search_term_string}"},"query-input":"required name=search_term_string"}}]} {"@context":"https://schema.org","@type":"TechArticle","headline":"Plastic Injection Molding DFM: Why Adding More Plastic Can Make a Part Worse","url":"https://daily.dev/posts/plastic-injection-molding-dfm-why-adding-more-plastic-can-make-a-part-worse-iwq8oemdo","mainEntityOfPage":{"@type":"WebPage","@id":"https://daily.dev/posts/plastic-injection-molding-dfm-why-adding-more-plastic-can-make-a-part-worse-iwq8oemdo"},"datePublished":"2026-07-25T07:33:00.809Z","dateModified":"2026-07-25T07:34:34.971Z","description":"Uneven wall thickness in plastic injection-molded parts is a hidden but costly design flaw. Adding more plastic doesn't automatically improve strength — it can...","image":"https://media.daily.dev/image/upload/f_auto,q_auto/v1/posts/4a9bab8feb77f2a427ca4b134db3113f?_a=AQAEuop","thumbnailUrl":"https://media.daily.dev/image/upload/f_auto,q_auto/v1/posts/4a9bab8feb77f2a427ca4b134db3113f?_a=AQAEuop","isAccessibleForFree":true,"articleSection":"Medium","inLanguage":"en","publisher":{"@type":"Organization","name":"daily.dev","url":"https://daily.dev","logo":{"@type":"ImageObject","url":"https://daily.dev/apple-touch-icon.png","width":180,"height":180}},"author":{"@type":"Organization","name":"Medium","logo":"https://media.daily.dev/image/upload/t_logo,f_auto/v1/logos/medium","url":"https://daily.dev/sources/medium_js"},"commentCount":0,"discussionUrl":"https://daily.dev/posts/plastic-injection-molding-dfm-why-adding-more-plastic-can-make-a-part-worse-iwq8oemdo","interactionStatistic":[{"@type":"InteractionCounter","interactionType":{"@type":"LikeAction"},"userInteractionCount":0},{"@type":"InteractionCounter","interactionType":{"@type":"CommentAction"},"userInteractionCount":0}],"keywords":"manufacturing","timeRequired":"PT9M"} {"@context":"https://schema.org","@type":"BreadcrumbList","itemListElement":[{"@type":"ListItem","position":1,"name":"Home","item":"https://daily.dev"},{"@type":"ListItem","position":2,"name":"Medium","item":"https://daily.dev/sources/medium_js"},{"@type":"ListItem","position":3,"name":"Plastic Injection Molding DFM: Why Adding More Plastic Can Make a Part Worse"}]} ```