The undercut issue to be improved by some post-processing techniques

If the mold design cannot be adjusted, some post-processing techniques can be used to improve the undercut issue. Here are several common post-processing methods as follow.

1.Hand Grinding: For small batch production or individual products, the undercut part with hand grinding is a simple and direct method.

2.Machining: Remove or modify undercut parts by using machining techniques such as milling, grinding or drilling.

3.Chemical Treatment: Use chemical solvents or corrosive agents to soften the plastic and then remove the undercut parts.

4.Heat Treatment: Use heat treatment to soften the plastic material, and then use tools to remove the undercut parts.

5.Ultrasonic Cutting: Use ultrasonic cutting technology to precisely remove undercut parts, which is suitable for hard plastics.

6.Water Cutting: Water jet can produce a high-velocity flow for precise cutting of undercuts without causing thermal damage to the material.

7.Laser Cutting: Laser cutting technology can provide high-precision cutting and is suitable for removing complex undercut shapes.

8.Cutting Inside The Mold: Cutting lines or cutting edges are set inside the mold, which makes the cutting completed when the product is demoulded.

9.Demoulding Tools: Separate the product from the undercut area by making special demoulding tools, such as demoulding knives, pry bars, etc..

10.Vibration-assisted demolding: Using a vibration table or ultrasonic vibration to assist demolding can remove undercut parts at times.

11.Mechanical Stretching: For plastic materials with a certain degree of elasticity, it can try to use mechanical stretching to break undercut parts.

12.Solvent Wipe: Use a specific solvent to wipe the undercut part to soften it and make it easier to remove.

13.Belt Sanding or Sand Blasting: Use belt sanding or sand blasting techniques to smooth the edges of undercut parts.

14.Hot Air Purge or Hot Water Bath: Hot air purge or hot water bath can be used in the product to soften the plastic of the undercut part which can be removed by hand or tools.

Each post-processing technology has its applicable scenarios and limitations. When choosing a post-processing method, it needs to consider some factors such as product material, complexity of undercuts, production batch, cost, and processing efficiency. In some cases, it may be necessary to combine multiple technologies to achieve the optimum efficiency. If the post-processing process is complex or costly, it may need to re-evaluate the feasibility of the product design and mold design.