Mold Undercrust for Snap-In Enclosure

Do you mean undercuts molded without moveable/retractable mold features?

Depends on type of plastic, etc.etc. What does the end product do?

You could get away with .062 in a properly designed tool, maybe more.

Depends on your molder and how much time he's willing to spend on it.

I am designing a 2 part shell for an item, let's say the closest thing I can compare it to would be a USB Jump Drive. It is maybe 2 1/2" lg x 1 3/8 wide by maybe 7/16 thick overall. The shell would be split into two thicknesses 7/32" each with features like ledges or fingers to grip from one half the shell to the other. The customer wants to be able to snap it together instead of screws or cementing, and also for some reason wants to be able to pull the 2 shell halves apart, then put them back and have a secure joining.

Don't have time to go into it, but it is doable.

I often take molded shells apart because I understand how they are molded and joined.

Buy some stuff that you think is snapped together and destroy it and see how it's joined.

Next week

Can the case have holes through the side? A hole from the outside of the case forming the undercut will make the mold easier to build, and also allow someone to insert a small screwdriver or pin to push the snap finger back to allow disassembly.