Case Study: How Professional DFM Analysis Accelerated a TPU Project for an Australian Client

Case Study: How Professional DFM Analysis Accelerated a TPU Project for an Australian Client Introduction In December 2025, Jeancen Mold Company partnered with an Australian client to develop a spec

Introduction

In December 2025, Jeancen Mold Company partnered with an Australian client to develop a specialized TPU (Thermoplastic Polyurethane) component. What began as a simple inquiry about material capabilities and MOQ quickly evolved into a successful manufacturing partnership, with the first order confirmed in just 10 days.

Figure 1: Technical specifications for the Australian TPU project.

The Challenge

The client required high-precision molding for a TPU part with a Shore Hardness of 90A. TPU is known for its unique shrinkage characteristics and potential for surface defects if the mold design is not optimized. The client needed a partner who could provide more than just a quote—they needed deep engineering guidance to ensure mass production stability.

Our Solution: Engineering-First Approach

Upon receiving the 3D design, Jeancen’s engineering team performed a comprehensive DFM (Design for Manufacturing) analysis. We focused on critical areas that often cause issues in TPU molding:

1. Wall Thickness & Gate Optimization

We performed a color-mapped wall thickness analysis to identify potential "hot spots." By identifying thicker sections, we recommended the optimal gate location to prevent sink marks and ensure uniform material flow.

2. Draft Angle & Texture Management

Since the part required a heavy texture (VDI 36), we recommended specific draft angles. Our analysis ensured that the part could be ejected smoothly without dragging or surface damage, even with the complex core-side geometry.

3. High-Quality Tooling Material

To guarantee mold longevity and part consistency, we selected S136 heat-treated steel for the core, ensuring the mold could handle the abrasive nature of certain TPU grades over long production runs.

The Result

By addressing potential risks during the design phase, we built immense trust with the client. The proactive DFM report shortened the decision-making cycle to just 10 days.

Today, we are proudly working on our third consecutive project. This success story proves that when engineering expertise meets a customer-centric attitude, great things happen.

"Every factory wants the big orders, but someone has to take the small ones seriously. At Jeancen, we value the trust behind every project."

Need Engineering Support for Your Next Project?

Whether you are working with TPU, ABS, or complex automotive-grade materials, Jeancen is here to help. We offer free DFM engineering suggestions in the early stages to help you reduce mold risks and improve production efficiency.

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