Testing & Analysis
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Testing & Analysis
Testing and analysis are indispensable aspect in product development, to ensure the quality, reliability, and consistency of product throughout the production process. By employing a comprehensive approach to testing and analysis, we optimize designs, enhance process efficiency and deliver high-quality products to meet the demands of diverse applications.
At SSR, our goal is to achieve an initial model or mock-up of a product right from the outset. This proactive approach is aimed at reducing costs, expediting delivery timelines, and circumventing the need for expensive aftermarket solutions.
1
Design Failure Mode and Effect Analysis (DFMEA)
Design Failure Mode and Effect Analysis (DFMEA) is an application of the Failure Mode and Effects Analysis (FMEA) that is specific to the design stage. The DFMEA allows the design team to document what they predict about a product’s potential failures before completing a design and use this information to mitigate the causes of failure. FMEA is the quintessential Six Sigma tool. It helps decrease defects while increasing customer satisfaction.
2
Rapid Prototyping
Prototyping is a way to validate the hypothesis that a product will solve the problem it is intended to solve. Although not fully functional by any means, a prototype often “looks” real enough that potential users can interact with it and provide feedback.
If the feedback reveals that the prototype is pretty far off the mark, then the company saves weeks or months from building something that won’t work in the real world. At the same time, a positive reaction to a prototype indicates the product concepts are on the right track, and development should proceed.
Hence, Rapid prototyping is an agile strategy used throughout the product development process. With this approach, 3-dimensional prototypes of a product or feature are created and tested to optimize characteristics like shape, size, and overall usability.
3
Mold Flow Analysis
Mold flow analysis is a simulation technique used to predict the flow of molten plastic within the mold cavity during the injection molding process. By analyzing factors such as flow rate, pressure distribution, and cooling rates, mold flow analysis helps optimize mold designs, identify potential defects and ensure uniform filling of the mold.
4
Material Testing
Before commencing production, it’s essential to conduct thorough material testing to assess the properties and characteristics of the chosen plastic resin. This includes testing for mechanical properties, such as tensile strength, impact resistance, and Flexural modulus, as well as thermal properties like melting point and heat resistance.
5
Dimensional Analysis
Dimensional analysis involves measuring and verifying the dimensions, tolerances, and geometric features of injection molded parts. This ensures that the final parts meet the specified design requirements and adhere to industry standards. Advanced metrology techniques, including coordinate measuring machines (CMMs) and 3D scanning, are commonly used for dimensional analysis.
6
Process Optimization
Testing and analysis are integral to process optimization efforts aimed at improving part quality, reducing cycle times, and minimizing production costs. By collecting data, conducting experiments, and analyzing results, injection molding processes can be fine-tuned for optimal performance and efficiency.
