{"id":4512,"date":"2026-10-27T03:50:40","date_gmt":"2026-10-27T03:50:40","guid":{"rendered":"https:\/\/www.teamrapidtooling.com\/blog\/?p=4512"},"modified":"2026-10-27T06:13:31","modified_gmt":"2026-10-27T06:13:31","slug":"injection-mold-undercut-design-guidelines-how-to-design-lifters-and-side-actions","status":"publish","type":"post","link":"https:\/\/www.teamrapidtooling.com\/blog\/injection-mold-undercut-design-guidelines-how-to-design-lifters-and-side-actions\/","title":{"rendered":"Injection Mold Undercut Design Guidelines: How to Design Lifters and Side Actions"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\">Undercuts are common in <a href=\"https:\/\/www.teamrapidtooling.com\/injection-molding-parts-c-10.html\" data-type=\"link\" data-id=\"https:\/\/www.teamrapidtooling.com\/injection-molding-parts-c-10.html\">injection molded parts<\/a>, especially in snap-fit housings, clips, enclosures, connectors, and components with side holes or internal locking features. <strong>Injection mold undercut design guidelines focus on selecting and designing lifters, side actions, or manual inserts to release undercuts reliably while optimizing mold complexity, tooling cost, and production efficiency.<\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Lifters and side actions are two common solutions. Both allow a mold to form features that would otherwise prevent part ejection, but they work differently and have different requirements for space, movement, tooling cost, and maintenance.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">For <strong>prototype tooling<\/strong>, <strong>bridge tooling<\/strong>, and <strong>low-volume injection molding<\/strong>, removable manual inserts can also be a practical option. They may reduce mold complexity and initial tooling cost when production quantities are limited and manual handling is acceptable.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This guide explains how to <a href=\"https:\/\/www.teamrapidtooling.com\/our-top-key-points-for-mold-design-a-45.html\" data-type=\"link\" data-id=\"https:\/\/www.teamrapidtooling.com\/our-top-key-points-for-mold-design-a-45.html\">design injection mold<\/a> undercuts, choose between lifters and side actions, and evaluate manual inserts for rapid tooling and low-volume production.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">What Is an Undercut in Injection Molding?<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">An undercut is a feature that prevents a molded part from being ejected directly along the mold-opening or ejection direction. It can be located inside or outside the part and may take the form of a hook, groove, hole, thread, or locking feature.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">If the mold does not provide a way to clear the undercut, the part may become trapped on the core, deform during ejection, or suffer surface damage.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Internal vs. External Injection Mold Undercuts<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Internal undercuts<\/strong> are features located inside a part or cavity, such as internal snap hooks, grooves, and locking tabs. They often require lifters, collapsible cores, removable inserts, or other specialized mechanisms.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>External undercuts<\/strong> are features on the outside of a part, such as side holes, external grooves, and protruding hooks. Side actions are commonly used when these features prevent the mold from opening or the part from being released.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The distinction is useful, but it is not an absolute rule. The correct mechanism depends on the undercut&#8217;s location, orientation, depth, surrounding geometry, and available space within the mold.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Why Undercuts Increase Mold Complexity and Cost<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Undercuts may require additional mold components, more machining, tighter fitting tolerances, and extra assembly work. Moving mechanisms also introduce wear points that need maintenance.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The effect on cost depends on the chosen solution. A simple manual insert may add labor during molding but keep the mold relatively inexpensive. An automatic side action may cost more initially but reduce handling time during production.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Engineers should therefore evaluate undercuts early in the design process instead of treating them as a tooling issue after the part geometry has been finalized.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Injection Mold Lifter Design vs. Side Action Design<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Lifters and side actions both release undercuts, but their movement and typical applications differ.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">A lifter generally moves with the ejector system and travels at an angle, creating the clearance needed to release an internal feature. A side action, also called a slide or side core, moves laterally to clear a feature before the molded part is ejected.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">How Injection Mold Lifters Work<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">A lifter is mounted to the ejector system, often at an angle. When the ejector plate advances, the lifter moves forward and sideways, clearing the undercut as the part is pushed off the core.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Lifters are commonly used for internal snap features, locking hooks, and grooves that can be released through coordinated ejection and lateral movement.<\/p>\n\n\n\n<figure class=\"wp-block-video\"><video height=\"1920\" style=\"aspect-ratio: 1080 \/ 1920;\" width=\"1080\" controls src=\"https:\/\/www.teamrapidtooling.com\/blog\/wp-content\/uploads\/2026\/10\/Lifter.mp4\"><\/video><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">Their main design constraints include the available ejection stroke, lifter angle, required lateral clearance, supporting structure, and the space available inside the mold.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">How Injection Mold Side Actions Work<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">A side action uses a movable core or slide to form a feature that cannot be released along the main mold-opening direction.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">In a conventional angle-pin arrangement, the slide moves into position when the mold closes. When the mold opens, the angle pin drives the slide away from the molded part. A locking mechanism or suitable support holds the slide securely against injection pressure during filling and packing.<\/p>\n\n\n\n<figure class=\"wp-block-video\"><video height=\"1080\" style=\"aspect-ratio: 2336 \/ 1080;\" width=\"2336\" controls src=\"https:\/\/www.teamrapidtooling.com\/blog\/wp-content\/uploads\/2026\/10\/Slider.mp4\"><\/video><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">Side actions are frequently used for transverse holes, external grooves, and other features that require direct lateral core movement.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">When to Use a Lifter Instead of a Side Action<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li>A lifter is often a good choice when an internal undercut can be cleared during ejection and there is sufficient room for the angled movement.<\/li>\n\n\n\n<li>A side action is usually more appropriate when an external feature requires a separate lateral core or when the feature&#8217;s geometry cannot be released by a practical lifter arrangement.<\/li>\n<\/ul>\n\n\n\n<p class=\"wp-block-paragraph\">Neither mechanism is automatically the better choice. A deep internal hook, for example, may need a different solution if the lifter would be too long or weak. A simple external groove may be easier to form with a slide, but a redesign could eliminate the need for either mechanism.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Injection Mold Undercut Design Guidelines for Engineers<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Good undercut design starts with the part geometry and the mold-opening direction. The goal is to provide enough clearance for release while maintaining the part&#8217;s required strength, appearance, and function.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Design Undercut Depth, Clearance, and Release Travel<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The required movement depends on the depth of the undercut and the direction in which the mechanism moves. The core must clear the interfering geometry before the part can be ejected or the mold can complete its opening sequence.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">For a lifter, engineers need to consider both the ejector stroke and the lateral movement generated by the lifter angle. For a side action, the slide must travel far enough to clear the entire undercut, including any practical clearance needed to prevent interference.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Do not size a mechanism from undercut depth alone. Check the complete three-dimensional geometry, adjacent walls, draft, part deformation limits, and the available space within the mold.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Apply Suitable Draft Angles to Undercut Features<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Draft helps molded surfaces release from the core and cavity. Even when a feature requires a lifter or side action, draft on the surrounding walls can reduce friction and the risk of sticking.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The appropriate draft depends on the resin, surface texture, wall depth, geometry, and finish requirements. Textured surfaces often require more draft than smooth surfaces.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Draft does not eliminate a true undercut, but it can make the release process more reliable once the undercut has been cleared.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Check Wall Thickness, Ribs, and Local Geometry<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Undercuts should be evaluated alongside wall thickness, ribs, bosses, and nearby openings. Deep features or closely spaced walls may leave insufficient room for a lifter, slide, or manual insert.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Sharp transitions and excessive local thickness can also contribute to sink marks, uneven cooling, or dimensional variation.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Where possible, use consistent wall thickness and avoid unnecessary geometry around the undercut. A small design change may simplify the tooling without affecting the part&#8217;s function.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Consider Parting Lines and Mold Opening Direction<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The parting line and mold-opening direction strongly influence undercut requirements. A different part orientation may allow a feature to be formed by the main core and cavity instead of a moving mechanism.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Before adding a slide or lifter, evaluate whether the part can be repositioned, the parting line adjusted, or the undercut modified without compromising appearance or function.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This is often one of the most cost-effective ways to simplify injection mold design.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Injection Mold Lifter Design: Key Design Considerations<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Lifter performance depends on the relationship between undercut geometry, angled movement, ejection travel, and mechanical support.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Select the Lifter Angle and Ejection Stroke<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The lifter angle determines how much lateral movement is generated during ejection. A steeper angle can produce more lateral movement for a given axial stroke, but it may also increase friction and side loading.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The required lateral clearance must be calculated from the undercut geometry and the lifter&#8217;s actual direction of movement. The ejector stroke must provide enough travel to clear the feature before the part is forced off the core.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">There is no single lifter angle that suits every application. The final choice depends on the mold layout, available stroke, lifter length, supporting structure, and required release distance.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Check Lifter Strength, Guidance, and Wear<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">A lifter must withstand repeated movement and the forces generated during ejection. A long or slender lifter may deflect, especially if its support and guidance are inadequate.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The design should provide suitable guidance, contact surfaces, and access for maintenance. Lubrication and wear protection should follow the mold designer&#8217;s material and maintenance specifications.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">For production tooling, consider the expected shot count and the difficulty of replacing worn components. A mechanism that works during initial sampling may still need improvements before sustained production.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Design Internal Undercuts for Reliable Ejection<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Internal snap hooks and locking features should have enough clearance to release without excessive force. The feature must also retain sufficient strength to perform its intended function after molding.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">For flexible parts, controlled elastic deformation may help release an undercut, but this approach depends on the resin, feature dimensions, and allowable strain. Brittle materials or rigid features may need a mechanical release solution instead.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">If a lifter requires excessive movement or leaves too little material for a reliable mechanism, consider a removable insert, a collapsible core, or a revision to the part geometry.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Injection Mold Side Action Design: Key Design Considerations<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Side actions must move far enough to release the part while maintaining alignment and resisting injection pressure during molding.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Determine Slide Travel and Side-Core Clearance<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Start with the full depth and shape of the undercut. Calculate the lateral movement required to clear the molded feature, then check the movement against the available space inside the mold.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The slide must also avoid interference with adjacent mold components, ejector plates, cooling channels, and other moving mechanisms.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Insufficient travel can cause the part to remain trapped or become damaged during ejection. Excessive travel, on the other hand, can increase mold size and complicate the mechanism unnecessarily.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Design Angle Pins, Slide Locks, and Wear Plates<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Angle pins commonly drive side slides in conventional molds. Wear plates and guide surfaces help maintain alignment as the slide moves through repeated cycles.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The slide must also be securely supported during injection. Depending on the mold design, a locking block or another suitable locking arrangement may be needed to resist the pressure acting on the side core.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Component sizing and locking arrangements should be based on the mold geometry, expected loading, material selection, and the tooling supplier&#8217;s design standards.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Prevent Flash at Side-Action Shutoff Surfaces<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Flash can form around side cores when shutoff surfaces do not fit correctly, become worn, or fail to resist injection pressure.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The design should provide appropriate contact geometry, adequate support, and accessible surfaces for inspection and maintenance. Mold alignment, machining accuracy, and wear control are also important.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">If flash appears near an undercut, check the shutoff surfaces and slide support rather than assuming that injection settings alone are responsible.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Common Injection Mold Undercut Design Mistakes<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Many undercut problems can be prevented by reviewing release movement and mechanism access before the mold is manufactured.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Insufficient Release Clearance or Travel<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">A lifter or slide may move as intended but still fail to clear the undercut completely. The result can be part deformation, ejection marks, or damage to the mold.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Verify the required clearance against the full feature geometry and confirm that the mechanism completes its release movement before ejection proceeds.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Overly Complex Mechanisms for Simple Undercuts<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Adding a side action or lifter without considering alternative solutions can increase tooling cost and maintenance requirements.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Review the parting line, opening direction, and feature geometry first. For low-volume projects, a manual insert may also be worth considering if the feature can be accessed and released safely.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Ignoring Mold Maintenance and Production Requirements<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">A mechanism should be selected for the expected production conditions, not just for the first successful sample.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Consider the number of parts required, cycle-time expectations, operator handling, mechanism wear, and future production plans. These factors may change the preferred solution even when the part geometry stays the same.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Designing Injection Mold Undercuts for Rapid Tooling and Low-Volume Production<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Rapid tooling and low-volume injection molding require a balance between initial mold cost, lead time, part quality, and production labor. A fully automated mechanism is not always necessary for a short run, but a low-cost mold can become expensive if every cycle requires extensive manual work.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The right approach depends on undercut geometry, order quantity, resin, part function, and whether the mold will be used for future production.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Reduce Tooling Cost by Simplifying Undercut Geometry<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Small changes to hook depth, feature orientation, wall layout, or parting-line location can reduce the complexity of the mold.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Before specifying a lifter or side action, review whether the undercut can be removed, reduced, or formed from a different direction without affecting part performance.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">For rapid tooling, these early design decisions can help avoid unnecessary machining and reduce the risk of late mold modifications.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Choose Mechanisms for Prototype and Bridge Tooling<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Prototype tooling is often used to validate geometry, fit, material behavior, and assembly before committing to production tooling. A manual insert may be appropriate when the part is still being evaluated and production quantities are limited.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Bridge tooling may require a different decision. If the tool will produce a substantial batch while production tooling is being prepared, the labor and cycle-time costs of manual inserts may outweigh their initial tooling savings.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">If future volumes are expected to grow, consider whether the mold can be designed or modified to accommodate a lifter or side action later. Discussing this possibility during the initial DFM review can help avoid an expensive redesign.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Validate Undercut Release During Mold Trials<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Before approving the mold, confirm that the selected mechanism releases the part without excessive force, deformation, or surface damage.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Check dimensional accuracy, flash, ejection marks, mechanism movement, and repeatability. For manual inserts, verify that operators can install, locate, remove, and reinstall the inserts consistently.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">A successful first sample is not enough on its own. The release method should remain reliable across repeated cycles and suit the planned production process.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Another Option: Use Removable Manual Inserts to Release Undercuts in Low-Volume Production<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">A removable manual insert is a removable mold component used to form an undercut or other feature that would otherwise prevent the part from being released. The insert is removed from the molded part after molding, allowing the part to be taken out without relying on an automatic lifter or side action for that feature.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Removable manual inserts can be useful for prototypes, bridge tooling, and small production runs because they may reduce mold complexity and initial tooling cost. &nbsp;However, manual inserts add labor to each molding cycle. They can increase cycle time and introduce risks related to incorrect placement, wear, handling damage, and inconsistent assembly. The insert must also be securely located and supported against injection pressure.<\/p>\n\n\n\n<figure class=\"wp-block-video\"><video height=\"1920\" style=\"aspect-ratio: 1080 \/ 1920;\" width=\"1080\" controls src=\"https:\/\/www.teamrapidtooling.com\/blog\/wp-content\/uploads\/2026\/10\/Removal-Manual-Insert.mp4\"><\/video><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">For this reason, removable manual inserts are most attractive when production volume is limited, the insert is accessible, and manual handling is acceptable. For higher-volume or highly automated production, a lifter or side action may provide better long-term efficiency.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Choose Between Removable Manual Inserts, Lifters, and Side Actions<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The following comparison can help narrow the options during design for manufacturability (DFM).<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><td><strong>Consideration<\/strong><\/td><td><strong>Removable<\/strong> <strong>Manual insert<\/strong><\/td><td><strong>Lifter<\/strong><\/td><td><strong>Side action<\/strong><\/td><\/tr><tr><td>Typical use<\/td><td>Accessible undercuts in prototypes and short runs<\/td><td>Suitable internal undercuts<\/td><td>External undercuts and side features<\/td><\/tr><tr><td>Initial tooling complexity<\/td><td>May be lower<\/td><td>Requires an integrated moving mechanism<\/td><td>Requires a slide and associated components<\/td><\/tr><tr><td>Part release<\/td><td>Manual insert removal<\/td><td>Angled movement during ejection<\/td><td>Lateral core movement<\/td><\/tr><tr><td>Labor per cycle<\/td><td>Higher<\/td><td>Usually lower<\/td><td>Usually lower<\/td><\/tr><tr><td>Cycle time<\/td><td>Often longer<\/td><td>Depends on ejection and mechanism<\/td><td>Depends on slide movement and mold cycle<\/td><\/tr><tr><td>Best-fit production<\/td><td>Prototypes and low volumes<\/td><td>Repeated production with suitable internal geometry<\/td><td>Repeated production with suitable side features<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">These are general comparisons, not universal rules. Some undercuts are unsuitable for manual inserts because the insert cannot be accessed, removed, or supported reliably. Similarly, not every internal feature can be released by a lifter, and not every external feature requires a side action.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The final decision should account for the complete mold design and the total cost of producing the required quantity\u2014not just the initial tooling quote.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Lifter vs. Side Action: How to Choose the Right Solution<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The most suitable solution depends on the feature geometry, mold layout, required production quantity, and acceptable level of manual handling.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><td><strong>Design consideration<\/strong><\/td><td><strong>Lifter<\/strong><\/td><td><strong>Side action<\/strong><\/td><\/tr><tr><td>Typical application<\/td><td>Internal undercuts<\/td><td>External undercuts and side holes<\/td><\/tr><tr><td>Main movement<\/td><td>Angled movement linked to ejection<\/td><td>Lateral movement of a slide or core<\/td><\/tr><tr><td>Main design concern<\/td><td>Ejection stroke and lateral clearance<\/td><td>Slide travel, locking, and shutoff<\/td><\/tr><tr><td>Potential advantage<\/td><td>Combines undercut release with ejection<\/td><td>Provides direct access to side features<\/td><\/tr><tr><td>Key limitation<\/td><td>Needs space and suitable ejection geometry<\/td><td>Adds slide components and alignment requirements<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">Manual inserts should also be considered when designing for prototypes and low-volume production. They may reduce the initial mold investment, but the additional handling and cycle time must be included in the cost comparison.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>A practical selection process is to:<\/strong><\/p>\n\n\n\n<ol class=\"wp-block-list\">\n<li>Identify the undercut&#8217;s location, depth, and release direction.<\/li>\n\n\n\n<li>Check whether changing the part geometry or mold opening direction can eliminate the undercut.<\/li>\n\n\n\n<li>Evaluate manual inserts if the volume is low and the insert can be accessed and supported safely.<\/li>\n\n\n\n<li>Evaluate lifters and side actions when an integrated mechanism offers better release reliability or production efficiency.<\/li>\n\n\n\n<li>Compare tooling cost, labor, cycle time, maintenance, and future volume before making the final decision.<\/li>\n<\/ol>\n\n\n\n<p class=\"wp-block-paragraph\">For complex parts, review the undercut during DFM before finalizing the mold design. This helps align the release method with the part&#8217;s functional requirements and production plan.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Frequently Asked Questions About Injection Mold Undercut Design<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\">What is the difference between a lifter and a side action in injection molding?<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">A lifter moves at an angle with the ejector system to clear an undercut as the part is ejected. A side action moves a core laterally to release a feature that prevents straight mold opening or ejection.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">How do you calculate the required travel for an injection mold lifter?<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The required lateral travel depends on the undercut depth, the lifter&#8217;s movement direction, and the angle convention used in the design. For a simplified geometry, if the lifter angle is measured from the ejection direction, the lateral movement is approximately the axial stroke multiplied by the tangent of that angle. The calculation must be checked against the actual geometry, available stroke, and required clearance.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">When does an injection molded part need a side action?<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">A side action is commonly required when a hole, groove, or other feature is oriented across the main mold-opening direction and cannot be released by a straight-pull mold or another practical release method.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Can injection mold undercuts be designed without lifters or side actions?<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Yes. Depending on the geometry, the undercut may be eliminated through part redesign, formed from a different mold-opening direction, or released using a suitable manual insert or collapsible core. Flexible stripping may also work for certain materials and shallow features, provided the part can deform without damage.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Do lifters and side actions increase injection mold cost?<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">They generally add components, machining, fitting, and maintenance requirements. However, they may reduce labor and cycle time during production. The total cost depends on the mechanism, production quantity, and operating requirements.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Are lifters and side actions suitable for rapid tooling and low-volume injection molding?<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Yes. They can be appropriate when reliable, repeatable release is needed. For very small runs, a manual insert may offer a lower-cost alternative if the geometry allows safe and practical removal. The best option depends on tooling budget, lead time, production quantity, and expected future demand.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Plan Your Injection Mold Undercuts Before Tooling<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Undercuts do not automatically require complex mold mechanisms. A careful review of the part geometry, release direction, and production requirements can reveal opportunities to simplify the design.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Lifters are useful for many internal undercuts, while side actions are commonly used for external features and transverse holes. Manual inserts provide another option for accessible undercuts in prototype and low-volume production, where reducing initial tooling cost may be more important than minimizing cycle time.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Contact Us<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">At <a href=\"https:\/\/www.teamrapidtooling.com\/\" data-type=\"link\" data-id=\"https:\/\/www.teamrapidtooling.com\/\">TEAM Rapid<\/a>, reviewing undercut geometry during DFM helps identify practical tooling approaches for prototypes, bridge production, and injection molded parts. Learn more about our <a href=\"https:\/\/www.teamrapidtooling.com\/injection-molding-services-t-24.html\">injection molding services<\/a> and <a href=\"https:\/\/www.teamrapidtooling.com\/rapid-tooling-services-t-23.html\">rapid tooling services<\/a> to evaluate a suitable manufacturing route for your project.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Undercuts are common in injection molded parts, especially in snap-fit housings, clips, enclosures, connectors, and components with side holes or internal locking features. Injection mold undercut design guidelines focus on selecting and designing lifters, side actions, or manual inserts to release undercuts reliably while optimizing mold complexity, tooling cost, and production efficiency. Lifters and side&#8230;<\/p>\n","protected":false},"author":2,"featured_media":4518,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_kad_post_transparent":"","_kad_post_title":"","_kad_post_layout":"","_kad_post_sidebar_id":"","_kad_post_content_style":"","_kad_post_vertical_padding":"","_kad_post_feature":"","_kad_post_feature_position":"","_kad_post_header":false,"_kad_post_footer":false,"_kad_post_classname":"","footnotes":""},"categories":[1],"tags":[],"class_list":["post-4512","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v18.7 (Yoast SEO v28.2) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Injection Mold Undercut Design Guidelines: How to Design Lifters and Side Actions -<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.teamrapidtooling.com\/blog\/injection-mold-undercut-design-guidelines-how-to-design-lifters-and-side-actions\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Injection Mold Undercut Design Guidelines: How to Design Lifters and Side Actions\" \/>\n<meta property=\"og:description\" content=\"Undercuts are common in injection molded parts, especially in snap-fit housings, clips, enclosures, connectors, and components with side holes or internal locking features. 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