Armal: Micro-Details for Optimizing the Toi-Toi Spray Unit

In technical molding, success often hinges on invisible details: a calibrated draft angle, a hidden injection point, an offset that ensures structural consistency. In this project, every micro-area was analyzed and optimized to match the material behavior and adapt it to the industrial scale with maximum precision.

Armal, a leader in the mobile sanitation services sector, requested a specific component for their Spray Unit, designed to deliver a delicate active ingredient while also resisting light but repeated stresses. The MPT Codesign team worked on three technical elements made of PA6 GF30, a material chosen for its strength and stability, aiming to achieve a smooth, flawless surface directly from the mold. This was all to be achieved with a two-cavity mold, ready for in-house production and in line with the aesthetic and functional standards required during assembly.

Each component was analyzed to identify geometric and structural issues that needed addressing in order to ensure clean, stable moldability, compatible with:

• The need for minimum draft angles (0.5°–1°) to prevent sticking and preserve the steel;
• A consistent 3 mm offset on the walls to ensure uniform filling;
• Adjustment of the molding axis in accordance with the technical calls made;
• Avoiding limitations on markings and date codes by inserting only the imprint number;
• Providing an invisible positioning of the injection points to ensure there are no aesthetic defects on the assembled part, and to prevent potential interference during assembly.

At the same time, the efficiency of the direct cooling system was verified, integrated on both levels of the mold, to ensure thermal stability and dimensional quality, even on structural parts made of PA6 GF30. The threaded holes identified on the mounting plates and the orientation of the circuits indicate a parallel cooling logic, optimized for a repetitive and reliable production cycle.

Every intervention was designed to take the project from its CAD form to a stable industrial configuration, technically coherent across the entire bill of materials, and ready to be put into production by the parent company, Armal. The customer can thus proceed with in-house production with certainty, reducing time and risks. Specifically, we focused on:

• Reorganization of the molding axes and movements to make geometries achievable and replicable;
• Targeted integration of injection points in protected zones, eliminating the need for post-molding finishing;
• Standardization of drafts and offsets, even on inclined surfaces with multiple movements;
• Simplification of the marking process, keeping only the essential production information (imprint number);
• Technical assessment of what is achievable and proposal of alternative solutions for critical elements.

The design concentrated on a two-cavity mold to ensure symmetric and balanced production of the main component of the Spray Unit. The mold structure and auxiliary movements were configured to ensure safe ejection and protection of the functional surfaces.

• The components were corrected and adapted to be moldable with precision, avoiding rework or subsequent compensations;
• Potential issues related to injection points, movements, teeth, or inconsistent thicknesses were eliminated;
• The coherence between function, process, and shape was restored, without compromising either aesthetics or robustness;
• The customer was able to clearly evaluate production limits and the most effective solutions to integrate them into their decision-making process.

In projects where everything hinges on a few hundredths of a millimeter, the value of codesign lies in the ability to translate material behavior into achievable geometries. MPT supported the client as a technical partner, analyzing and anticipating process limits to transform the component’s complexity into a part ready for serial production. This work confirms the effectiveness of continuous dialogue between designers, builders, and industrializers.
Want to co-design with us a compatible system that lasts over time, where all the pieces are in the right place? Contact our technical experts.