Warpage Analysis of 50-position Connector

The product exhibited unacceptable warpage after molding.  Design of Experiments (DOE) indicated that the problem could not be solved with process modifications alone;  design changes were necessary.  The Warpage analysis pointed to two critical areas in the geometry of the part:  the gated end-wall and the  perforated sections of the side walls.  These components were modified to reduce the differential shrinkage among the building elements of the Connector.  The second analysis indicated greatly improved flatness of the part.  The computed robust process was used for the production.