7 design errors that ruin molds and casting — and how to avoid each one

The 7 errors that ruin molds and casting

Error 1: Walls too thin. Minimum 0.8mm for direct casting, 1.2mm for rubber mold. Error 2: Closed geometries without ventilation channel. Every closed volume needs a gas exit channel (minimum 0.5mm diameter). Error 3: Unplanned undercuts. Analyze draft lines before designing for mold production. Error 4: Surface details below process resolution. Below 0.3mm detail depth: use high-resolution direct casting (SLA, 25 micron resolution). Error 5: Non-integrated bails and clasps. Design bail, post and clasp directly in the 3D file. Error 6: Incorrect proportions for commercial ring size. Use the measurement system of your primary market. Error 7: Exporting STL with low mesh resolution. Use minimum 0.01mm deviation tolerance in export settings.

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