Injection moulding<\/u><\/a>. You don't solve that kind of problem with process optimisation; you solve it in the design.<\/p>\n\n\n\nAt Eurotechniek 2026, we routinely carry out a DFM analysis before a mould is built. This analysis costs a few hundred euros and prevents correction costs running into thousands of euros. Most customers who start without DFM wish afterwards that they had done it.<\/p>\n\n\n\n
Choosing materials by feel<\/h2>\n\n\n\n
Material selection is a technical choice, not a gut feeling. Yet, we regularly see clients specify a material they know from a previous project, without checking if it is suitable for the new application. PP works excellently for domestic applications, but falls short under mechanical stress or chemical exposure.<\/p>\n\n\n\n
For example: a customer wanted to injection mould a housing in ABS for use in an outdoor environment. ABS is sensitive to UV light and will crumble with prolonged exposure to sunlight without stabilisers. The correct material for that application was ASA, which is visually similar but UV-stable. By making that choice, subsequent complaints and warranty issues were avoided.<\/p>\n\n\n\n
Material costs vary significantly. PP costs around 1.50 euros per kilogram, while PEEK can reach 80 euros or more. However, the correct material choice also determines cycle time, mould temperature, and tool lifespan. Eurotechniek 2026 provides advice based on functional requirements, the environment, and volume, not on whatever happens to be in stock.<\/p>\n\n\n\n
Skip prototypes to save time<\/h2>\n\n\n\n
Time pressure leads to the decision to skip prototyping phases. The feeling is understandable: a prototype costs money and delays the launch. But a prototype reveals design flaws that can amount to thousands of euros in correction work during mass production.<\/p>\n\n\n\n
A 3D-printed prototype provides insight into ergonomics, assembly, and dimensions. It does not replace an injection mould, but it does answer questions about design and function before that mould is built. An iteration on a 3D print costs 50 to 200 euros. The same iteration on a mould costs 1,000 to 5,000 euros.<\/p>\n\n\n\n
We prefer to work with a validation process: prototype, DFM analysis, T1 sample, and then series production. These steps may seem like extra work, but they shorten the overall lead time as fewer correction cycles are needed. Skipped steps always reappear in the process, only at a higher cost.<\/p>\n\n\n\n
Specifying tolerances without context<\/h2>\n\n\n\n
Tolerances on technical drawings are often carried over from previous use or standard tables without anyone considering whether they are feasible and necessary. Tolerances that are too tight increase production costs without always being technically required.<\/p>\n\n\n\n
Injection moulding has inherent process variation. A tolerance of plus or minus 0.05 mm is achievable for small, stable geometries in a stable material. The same tolerance for a large, flat component in glass fibre reinforced PA is not realistic without additional measures. These measures cost time and money.<\/p>\n\n\n\n
A specific case: A customer specified a positional tolerance of 0.03 mm on a connector's 80 mm long connection. Following consultation, it became apparent that the functional requirement was 0.10 mm. The adjustment to the drawing reduced inspection rejections from 12 percent to under 1 percent. Eurotechniek 2026 always discusses tolerances in relation to function and process, ensuring they are realistic and cost-effective.<\/p>\n\n\n\n
The mould investment seen as a one-off cost<\/h2>\n\n\n\n
A mould is not a disposable item, nor is it a perpetual investment requiring no maintenance. Many companies treat mould investment as a one-off expense, failing to account for maintenance, refurbishment, or replacement. This leads to production shutdowns at the worst possible moment.<\/p>\n\n\n\n
A standard P20 steel mould will last for 500,000 to 1,000,000 cycles with normal maintenance. Without regular cleaning, lubrication, and inspection, that lifespan will decrease significantly. Cracks in the cavity, wear on the ejector pins, or leaks in the cooling circuit are early warning signs that can be identified with planned maintenance.<\/p>\n\n\n\n
We carry out mould reviews for customers after agreed cycle intervals. This prevents unexpected production downtime. A \u20ac800 overhaul is easier to plan for than an urgent \u20ac4,000 repair in the middle of a critical series order. Eurotechniek 2026 actively manages moulds, so you can focus on your own schedule.<\/p>\n\n\n\n
Involving suppliers late in new product development<\/h2>\n\n\n\n
Product development is too often seen as an internal process. The supplier receives a finished design and the order to produce it. However, a supplier who is involved early on can see opportunities that are not visible internally.<\/p>\n\n\n\n
An injection moulding partner collaborates on gate locations that reduce mould costs. On wall thicknesses that shorten cycle times. On material combinations that enable the 2K process without post-assembly costs. That knowledge resides with the supplier, not with the design engineer who might be designing their first injection moulded product.<\/p>\n\n\n\n
At Eurotechniek 2026, we invite customers to share their designs early in the process, even if they aren't yet complete. A 70 percent complete drawing yields more than a finalised drawing that is already set in stone. Thinking along in the early stages is cheaper than correcting later. That principle applies to every new product.<\/p>\n\n\n\n
Frequently asked questions about product development errors<\/h2>\n\n\n\nWhen is it too late to make changes to a design?<\/h3>\n\n\n\n
Technically, a design can always be modified, but the costs increase the further along in the process you are. Modifications for mould construction are relatively inexpensive. Modifications after the first T1 samples cost more, as the mould has already been built. Modifications during series production are the most expensive, in both time and money. Therefore, start early with DFM and involve your production partner right from the concept design phase. Eurotechniek 2026 also provides feedback on early sketch designs.<\/p>\n\n\n\n
How do I know if my tolerances are realistic for injection moulding?<\/h3>\n\n\n\n
This depends on the material, the size of the part, and the geometry. As a rule of thumb, for small, symmetrical parts made of stable amorphous material, tolerances of plus or minus 0.05 to 0.10 mm are achievable. For large or fibreglass-reinforced parts, you should expect plus or minus 0.15 to 0.30 mm or more. Have your tolerances assessed in a DFM analysis before ordering the mould. This will tell you what is achievable and what the functional requirement truly demands.<\/p>\n\n\n\n
What is the risk of a cheap mould from low-wage countries?<\/h3>\n\n\n\n
A low mould price might seem attractive, but it carries risks. The quality of the steel, machining accuracy, and the mould's own dimensional tolerances vary. A mould that doesn't have the right hardness or is poorly cooled will lead to quality problems that you pay for in higher rejection rates and longer cycle times. Furthermore, remote adjustments and maintenance are difficult to organise. Eurotechniek 2026 builds moulds in Europe, with traceable material certificates and direct access for refurbishment and maintenance.<\/p>\n\n\n\n
Preventing errors starts with the right partner<\/h2>\n\n\n\n
Product development is always a interplay of design, materials, process, and planning. Those who align these elements early on create better products at lower costs. The mistakes in this article are avoidable, not unavoidable.<\/p>\n\n\n\n
Contact Eurotechniek 2026 via euro-techniek.nl. We'll review your design and provide honest advice on manufacturability, materials, and production costs.<\/p>","protected":false},"excerpt":{"rendered":"
Veel productontwikkeltrajecten lopen vertraging op of lopen uit de kosten door fouten die vroeg in het proces worden gemaakt. Verkeerde materiaalkeuzes, ontwerpen die niet maakbaar blijken, te krappe toleranties of een matrijs die te laat wordt betrokken: het zijn herkenbare valkuilen. In dit artikel zetten we de meest gemaakte fouten bij productontwikkeling op een rij…<\/p>","protected":false},"author":11,"featured_media":3655,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_seopress_titles_title":"4 Fouten in Productontwikkeling Voorkomen | Eurotechniek - 2026","_seopress_titles_desc":"Ontdek hoe je kostbare ontwerpfouten voorkomt. DFM-analyse, materiaalkeuze & prototyping: bespaar duizenden euros in correctiewerk.","_seopress_robots_index":"","_seopress_robots_follow":"","_seopress_robots_imageindex":"","_seopress_robots_snippet":"","_seopress_robots_primary_cat":"","_seopress_robots_breadcrumbs":"","_seopress_robots_freeze_modified_date":"","_seopress_robots_custom_modified_date":"","_seopress_robots_canonical":"","_seopress_social_fb_title":"","_seopress_social_fb_desc":"","_seopress_social_fb_img":"","_seopress_social_fb_img_attachment_id":0,"_seopress_social_fb_img_width":0,"_seopress_social_fb_img_height":0,"_seopress_social_twitter_title":"","_seopress_social_twitter_desc":"","_seopress_social_twitter_img":"","_seopress_social_twitter_img_attachment_id":0,"_seopress_social_twitter_img_width":0,"_seopress_social_twitter_img_height":0,"_seopress_redirections_value":"","_seopress_redirections_enabled":"","_seopress_redirections_enabled_regex":"","_seopress_redirections_logged_status":"","_seopress_redirections_param":"","_seopress_redirections_type":0,"_seopress_analysis_target_kw":"","_seopress_news_disabled":"","_seopress_video_disabled":"","_seopress_video":[],"_seopress_pro_schemas_manual":[],"_seopress_pro_rich_snippets_disable_all":"","_seopress_pro_rich_snippets_disable":[],"_seopress_pro_schemas":[],"_yoast_wpseo_title":"","_yoast_wpseo_metadesc":"","_yoast_wpseo_focuskw":"","_yoast_wpseo_canonical":"","rank_math_title":"","rank_math_description":"","rank_math_focus_keyword":"","rank_math_canonical_url":"","_aioseo_title":"","_aioseo_description":"","_aioseo_keywords":"","_aioseo_canonical_url":"","footnotes":""},"categories":[1],"tags":[],"class_list":{"0":"post-4220","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-nieuws"},"acf":[],"_links":{"self":[{"href":"https:\/\/euro-techniek.nl\/en\/wp-json\/wp\/v2\/posts\/4220","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/euro-techniek.nl\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/euro-techniek.nl\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/euro-techniek.nl\/en\/wp-json\/wp\/v2\/users\/11"}],"replies":[{"embeddable":true,"href":"https:\/\/euro-techniek.nl\/en\/wp-json\/wp\/v2\/comments?post=4220"}],"version-history":[{"count":0,"href":"https:\/\/euro-techniek.nl\/en\/wp-json\/wp\/v2\/posts\/4220\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/euro-techniek.nl\/en\/wp-json\/wp\/v2\/media\/3655"}],"wp:attachment":[{"href":"https:\/\/euro-techniek.nl\/en\/wp-json\/wp\/v2\/media?parent=4220"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/euro-techniek.nl\/en\/wp-json\/wp\/v2\/categories?post=4220"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/euro-techniek.nl\/en\/wp-json\/wp\/v2\/tags?post=4220"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}