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Plastic Product Design
SARATH BABU MADDUKURI
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Index Over View of Plastic Product Design Polymer Fundamentals
Plastic Product Design Steps Plastic Material Selection Process Plastic Product Design Guidelines Plastic Manufacturing Process Basics of Injection Mold
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Product Design Environment
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Product Design & Development Steps
End Use Requirement a) Anticipated Structural Requirement Loads- Stresses a material will be subjected Rate of Loading Duration of Loading Impact Forces Vibration Foreseeable Misuse b) Anticipated Environment Temp Extremes c) Assembly and Secondary Operation d) Cost Limits e) Regulation Standards compliances
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Product Design & Development Steps
Establish Preliminary Design( Preliminary Concept Sketch and Sections) Select the material( Expected End Use Requirement, Material Data Sheets) a) Mechanical Properties used for essential component design calculations b) Other Relevant Properties 3 Modify Design as per the calculations results and desired function a) Specific property balance of selected grade b) Processing Limitation c) Assembly Method d) Cost of Modification
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Product Design & Development Steps
CAD/CAE Flow Analysis Stress Analysis 5 Prototype and Testing 6 End Use Testing
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Polymer Fundamentals
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Polymer Fundamentals
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Polymer Fundamentals
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INTRODUCTION Plastics were considered as “Replacing Materials”
Today’s world plastics are unreplacable materials on the same level as the classic materials: Primarily due to special combination of properties (profiles & material combinations) Plastics offers solutions, that are not possible with classic materials (Electronics, Medical care, Automotive industries etc.) Low weight, allows high accelerations & decelerations. Weather resistance (Corrosion) is better than resistance of metallic materials. Good Electrical Isolation properties (Housings of Electrical devices) Low manufacturing costs, especially with injection moulding technology.
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CLASSIFICATION : MATERIALS PLASTICS Thermoplastics High-Molecular
(Makromolecular) materails Organic Metals (as Ores) Thermosets Elastomers PLASTICS Thermoplastic elastomers Inorganic e.g. Glasses Crosslinkable (vulcanisible) Crosslinked:rubber Natural e.g. Wood Synthetic resp. Modified material MATERIALS
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Thermoplastics : They are thread-like molecules (Linear & Branched)
They are always Deformable – Fusible – Soluble. As degree of polymerisation (molecule length) increases strength & toughness increases, but flowability decreases. They are further classified as Amorphous thermoplastics & Crystalline (Partially crystalline) thermoplastics
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Amorphous Thermoplastics:
Bulky thread-like molecules, with unarranged interconnected macromolecular structures, similar to that of staples in a cotton pad. Transparent (Exception) : Styrol – copolymers with Butatein like ABS. Lower degree of Shrinkage & high precision can be achieved with less cost. High elastic properties between melt & freezing (Glass transition) temperature makes it to be produced at low holding pressure to avoid demoulding problems & high internal stress. They are more sensitive against solvents & the parts are more suspectable to stress cracking. Examples: Polycarbonate (PC) , Polyvinylchloride (PVC), Acrylonitrile – Butadiene – Styrene – Copolymer (ABS), etc.
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Acrylonitrile – Butadiene – Styrene – Copolymer (ABS) :
Structure : amorphous Density : 1,03 – 1,07 g/cm³ Elastic-Modulus : ~ 2400 N/mm² Properties : High rigidity & toughness also at low temperature to – 40º C, High Scratch resistance, High impact resistance, High suspectability to stress cracking Temperature limits: Short-Term ~ 100°C, Long Term ~ 85°C Surface Quality : High gloss surface can be achieved. Natural colour: opaque, non-transperant Manufacturing related properties : Low shrinkage & low tendency to wrap, Good Paintability & electroplatability. Applications : Automotive panels - (Interior & Exterior parts), etc.
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Acrylonitrile – Butadiene – Styrene – Copolymer (ABS) : Applications
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Polycarbonate (PC) : Structure : amorphous Density : 1,20 – 1,24 g/cm³ Elastic-Modulus : ~ 2200 N/mm² Properties : High strength & Hardness, Toughness at low temperature. High impact resistance, High suspectability to stress cracking Temperature limits: Short-Term ~ 135°C, Long Term ~ 100°C Surface Quality : High gloss surface can be achieved. Natural colour: Transperant Manufacturing related properties : Low shrinkage & low tendency to wrap, Good Paintability & electroplatability. Applications : Automotive panels - (Interior & Exterior parts), Headlights, Helmets, etc.
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Polycarbonate (PC) : Applications
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Polyvinylchloride (PVC) :
Structure : amorphous Density : 1,38 – 1,55 g/cm³ Elastic-Modulus : ~ 3000 N/mm² Properties : High hardness & stiffness. High impact resistance at low temperature till -5°C, below this brittleness increases. High suspectability to notch failure. Temperature limits: Short-Term ~ 70°C, Long Term ~ 60°C Surface Quality : High gloss surface can be achieved. Natural colour: Transperant till Opaque Manufacturing related properties : Low shrinkage High chemical resistance Applications : Ducts, Ventilation Channels, tubes, etc.
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Polyvinylchloride (PVC) : Applications
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Crystalline Thermoplastics:
Bulky thread-like slim molecules, which are alligned or with each other. Non transparent (translucent), naturally coloured good slip properties. Higher degree of Shrinkage due to higher package of molecules. Are less compressible than amorphous during hardening & freezing temperatures, hardly faces any demoulding problems. Due to higher shrinkage may form voids during cooling. Examples: Polyethylene (PE), Polypropylene (PP), Polyamide (PA), Polyacetal (POM) etc.
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Polyethylene (PE) : Structure : Semi crystalline Density : 0.91 – 0.96 g/cm³ Elastic-Modulus : ~ 1200 N/mm² Properties : High stiffness & Hardness. Good elastic properties. Practically unbreakable, ductile till -60°C Temperature limits: Short-Term ~ 135°C, Long Term ~ 80°C Surface Quality : High gloss surface can be achieved. Natural colour: milky white Manufacturing related properties : No water absorption, High Shrinkage & tendency to warpage High chemical resistance Applications : HR inserts, Ducts, Channels, etc.
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Polyethylene (PE) : Applications
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Polypropylene (PP) : Structure : Semi crystalline Density : 0.90 – 0.92 g/cm³ Elastic-Modulus : ~ 1450 N/mm² Properties : High stiffness & Hardness. Stability higher than PE. High flexural fatigue strength. Low impact strength at low temperature. Temperature limits: Short-Term ~ 140°C, Long Term ~ 100°C Surface Quality : High gloss surface can be achieved. Natural colour: Colourless shining through Manufacturing related properties : No water absorption, High Shrinkage & tendency to warpage High chemical resistance Applications : Car – Coverparts (Interior & Exteriors), etc.
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Polypropylene (PP) : Applications
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Polyamide (PA) : Structure : Semi crystalline Density : 1.02 – 1.15 g/cm³ Elastic-Modulus : ~ N/mm² Properties : High stiffness & impact strength. Good friction & wear resistance Temperature limits: Short-Term ~ 170°C, Long Term ~ 110°C Surface Quality : High gloss surface can be achieved. Natural colour: Translucent white-yellow Manufacturing related properties : Good flow properties & chemical resistance, Not so good shrinkage. Tendency to warpage. Applications : Car – (Inner, Outer), Bearings, Gear wheels, etc.
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Polyamide (PA) : Applications
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Thermosets : They are closely crosslinked, that is the reason they are non – thermoplastic. They are always Non - deformable – Infusible – Insoluble. Examples: Epoxy (EP), Phenol-formaldehyde (PF), etc.
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Elastomeres: They are loosely crosslinked, highly elastic & show very low plastic deformation. They are highly deformable –Insoluble. Examples: Natural Rubber (NR), Ethylen-Propylen rubber (EOM, EPDM), etc.
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Design Guidelines REQUIREMENT MATERIAL SELECTION
(For what ?, strength, assy) MATERIAL SELECTION (Cost , Manuf Prosess,Temp conds, Strength, Safety) PACKAGING DATA & KINEMATICS ( From customer) DECIDING SNAP & SCREW FIXING LOCATIONS (Locking 6 deg. Of freedom, DFA ) FIX TOOLING DIRECTION (Die-Draw direction, Minimum silder’s and aesthetic requirement ) (Packaging data, strength requirement) DECIDING STRENGTHING RIBS,LOCATIONS & GEOMETRY DRAFT ANGLES,RIBS WALL THICKNESS RATIO (As per design guidelines)
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Design Guidelines TOOLING FEASIBILITY DRAFT ANALYSIS A & B SURFACES
( Minimum core thickness, Slider ejection space, Sharp corners etc.) TOOLING FEASIBILITY DRAFT ANALYSIS A & B SURFACES SECTIONS WITH PACKAGING THROUGH SNAP & RIBS ( Tolerance issues)
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Design Guidelines Material Selection:
The wide variety of injection moldable thermoplastics often makes material selection a difficult task. Factors governing material selection Cost Functionality Assembly (Typically when bonded) Temperature Strength Government Regulations. Surface finish/aesthetic etc.
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Design Guidelines Wall thickness/ Base thickness:
Proper wall thickness determines success or demise of a product Like metals injection molded plastics also have normal working ranges of wall thickness. This can be taken into consideration while deciding wall thickness. Factors to be considered while deciding wall thickness. Structural strength of the part to be designed plays important role in deciding wall thickness. Normal working ranges of wall from chart for particular material selected. As a thumb rule 2.5mm. Prior experience or bench mark parts can also be referred while deciding on wall thickness.
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Design Guidelines Wall thickness/ Base thickness:
Once nominal wall thickness is decided, following are some design rules which should be followed. Maintain uniform wall thickness wherever possible which helps in material flow in mold, reduces risk of sink marks, Induced stresses & consideration of different shrinkage For non-uniform wall thickness change in thickness should not exceed 15% of nominal thickness & should transition gradually. At corner areas minimum fillet at inner side should be 50% of wall thickness.
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Design Guidelines Core-Cavity-Slider directions & Parting lines :
It is always recommended first to decide upon the core-cavity direction Generally core-cavity direction & parting line depends upon following parameters The shape & function of the component. Shape in turn is governed by A- Surface, packaging/environment data. Core-cavity & slider directions should be considered such that they do not appear on A-Surfaces, unless otherwise specified & accepted by the customer.
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Design Guidelines Draft Angles (On component walls):
Draft is necessary for ejection of part from the mold & are always Tooling (Die-Draw) & Slider direction. Recommended draft angle is minimum 1deg. Factors governing draft angle. Surface finish – Highly polished mold requires less draft than an unpolished mold. Surface Texture (Graining) – Draft increases with texture depth,normally 1 deg draft for every 0.025mm depth recommended. Draw depth – To keep the draft angle to minimum as thumb rule draft angle – draw depth charts are followed & often design engineer should discuss with tool maker.
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Design Guidelines Ribs :
Ribs should be used when needed for stiffness & strength or to assist in filling difficult areas. For structural parts where sink marks are no concerns -Rib base thickness can be 75%-80% of adjoining wall thickness For appearance parts where sink marks are objectionable: With texture (Graining) - Rib base thickness should not exceed 50% of adjoining wall thickness for part Without texture (Graining) - Rib base thickness should not exceed 30% of adjoining wall thickness. Some important points to consider while rib design. Draft angle on ribs should be minimum 0.5 deg per side Rib height should be 2.5 to 3 times of wall thickness for effective strength. Recommended to add multiple ribs instead of single large rib, Spacing between multiple ribs should be at least 2 times that of rib thickness. Fillets at base of ribs should be 0.5mm Minimum.
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Design Guidelines Bosses :
Usually designed to accept inserts, self tapping screws, drive pins etc for use in assembling or mounting parts. Some important points to consider while Boss design: The O.D of the boss should be ideally 2.5 times of screw diameter for self tapping screw applications. If O.D exceeds 50% of adjoining wall thickness, thinner wall boss of O.D 2 times or less of screw diameter can be considered with supported by ribs. Bosses should be attached to walls with ribs. Thickness at base of rib should not exceed 50% of adjoining wall thickness. Boss inside & outside diameters should have 0.5 deg draft per side.
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Design Guidelines Bosses :
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Design Guidelines Coring :
Coring in injection molding terms to addition of steel to mold for the purpose of removing plastic material in that area Coring is necessary to create Pocket or, Opening in the part or to reduce heavily walled section.
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Design Guidelines Openings :
Openings are desired in a part to eliminate sliders, cams, pullers, etc. to accommodate features like snaps As general thumb rule 5deg angle in the area of mating of core & cavity is required.
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Design Guidelines Assemblies : Types of assemblies :
Molded-in assembly Chemical bonding assembly Thermal welding assembly Assembly with fasteners. Molded-in Assembly : (Snap fit, Press fit, molded in threads etc.) This is generally the most economical method of assembly Assembly is fast, inexpensive & does not require any additional part or substance. Minimizes changes of improper assembly Some times tooling becomes complex & expensive.
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Design Guidelines Snap fit assembly :
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Design Guidelines Snap fit assembly : Important points to remember :
Y = Deflection Q values to be referred from Material graphs Important points to remember : Design for given assembly force or overlap length & material. Deflection required to assemble the part should always be less than maximum deflection(strain) for safe design. Snaps increase possibility of sliders wherever possible try to eliminate sliders by providing slot below snap or moving snap to outer edge of the part, if design permits.
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Design Guidelines Press fit assembly :
Press fit design is more critical in plastics (Thermoplastics as they creep (Stress or Relax). Good design should minimize stress on the plastic,by considering assembly tolerance between assembled parts & clamping force due to creep relaxation.
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Design Guidelines Adhesive joints assembly :
Two similar or dissimilar plastics can be assembled in a strong leak-tight bond by using adhesives. The choice of adhesive depends upon the application & the environment to which the part would be subjected. Some of adhesives are Polyurethanes, Epoxies, Cyanoacrylates, Silicones etc.
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Design Guidelines Bolts –Nuts - Screws :
Certain precaution must be taken while designing to reduce excessive compressive stress on the plastic. Larger head screw or larger washer is preferred as that contact area increases & stress reduces.
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Design Guidelines Molded in threads :
Coarse threads are preferred due to higher strength & torque limits. Generally 0.8 – 0.9 mm relief should be provided to prevent high stress at the end of the threads. To reduce the stress concentration minimum 0.25mm radius should be applied to the threads roots. External threads should be as far as possible located on parting lines to avoid need of unscrewing mechanism. Internal threads are usually formed by an unscrewing or collapse core.
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Design Guidelines Self Tapping Screws :
Further classified in 2 types Thread cutting & Thread forming Thread cutting screw is most used on brittle plastics such as thermosets & filled (50%) thermoplastics. They should not be reinstalled Thread forming screws is mostly used on thermoplastics. They can be reinstalled for 3 to 5 times. General Guidelines while using self-tapping fasteners: Thread engagement length 2.5 times screw diameter Boss diameter minimum 2 times of pilot hole diameter. Cored hole should have 0.25 ° to 0.5° draft. Holes should be counterbored or chamfered to a depth of 0.5mm to aid alignment & avoid cracking of boss. Sufficient clearance to be kept between screw end & bottom of the hole.
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TOLERANCE RANGE TO BE GIVEN ON DWGS:
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HOW SLIDERS & LIFTERS WORK ?
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SLIDER FOR UNDERCUT : Undercut Horn Pin Slide Molded Part
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SLIDER FOR UNDERCUT :
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SLIDER FOR UNDERCUT : Pulled Undercut
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SLIDER FOR UNDERCUT : Cover tool Molded part Horn Pin Locking Block
Spring Slide core
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SLIDER FOR UNDERCUT :
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SLIDER FOR UNDERCUT :
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SLIDER FOR UNDERCUT :
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LIFTER FOR UNDERCUT : Lifter Undercut Angled pin
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LIFTER FOR UNDERCUT :
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LIFTER FOR UNDERCUT :
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LIFTER FOR UNDERCUT : Molded part Lifter Undercut Horn pin Lose core
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LIFTER FOR UNDERCUT :
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LIFTER FOR UNDERCUT :
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LIFTER FOR UNDERCUT :
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HYDRAULIC CYLINDER FOR UNDERCUT :
Core pin Undercut Hydraulic Cylinder
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HYDRAULIC CYLINDER FOR UNDERCUT :
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HYDRAULIC CYLINDER FOR UNDERCUT :
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FORCED EJECTION :
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FORCED EJECTION :
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FORCED EJECTION :
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FORCED EJECTION :
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FORCED EJECTION :
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MULTIPLE UNDERCUTS Molded Part Slide Hydraulic Cylinder
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MULTIPLE UNDERCUTS
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MULTIPLE UNDERCUTS
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MULTIPLE UNDERCUTS
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MULTIPLE SLIDERS: Core Pin Locking Block Molded part Horn Pin Undercut
Spring Slide
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MULTIPLE SLIDERS:
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MULTIPLE SLIDERS:
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REFERENCES: Honeywell Injection Moulding Processing Guide (2002). Honeywell Design Soultions (2002). JCI Plastics Training Manual. Injection Moulding Design by Pye
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THANK YOU
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Product Design & Development Steps
Design For Stiffness Relation between load and deflection of the part is Stiffness Determined by material and geometry of the part Material Stress Strain Curves ( Young's Modulus) Design For Strength Max Load that can be applied to a part without resulting into part failure Determined by Tensile stress strain curves( Tensile Strength etc) Design for Behavior overtime Creep : Time dependent Increasing Strain under constant stress Stress Relaxation: Reduction of stress under constant strain
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Product Design & Development Steps
Design for Impact Performance Ability of material to withstand impulsive loading Factors: type of material, geometry, wall thickness, size of component, operating temp, rate of loading etc Design for appearance Sink Marks, weld lines, air traps, voids, streaks, delamination, jetting, gate marks etc Design for precision Design for moldability Design for Recyclability Design for automation
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Part Application Requirement
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Material Selection Process
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Material Selection Process
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Design Based Material Selection
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Guidelines for Injection Molded Design
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Plastic Processing
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Plastic Processing
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Plastic Processing-Injection Molding
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Plastic Processing-Injection Molding
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Plastic Processing-IMD
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Plastic Processing-Injection Molding
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Assembly Techniques for Plastic parts
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Assembly Techniques –Snap Fits
Snap fit cantilever beam type Snap fit cylindrical Type
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Assembly Techniques –Snap Fits
Factors for calculating cantilever beam for Snap fit
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Mold Design For Snap Fits
Assembly Techniques –Snap Fits Mold Design For Snap Fits
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Assembly Techniques –Spin Welding
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Assembly Techniques –Ultrasonic Welding
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Assembly Techniques –Hot Plate Welding
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Assembly Techniques –Adhesive Bonding
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Assembly Techniques –Ultrasonic Insertion
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Assembly Techniques –Screw and Bosses
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Assembly Techniques for Plastic parts
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Injection Mold
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Injection Mold
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Injection Mold- Slider and Stripper Plate
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Injection Mold- Stripper Plate
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Injection Mold- Stripper Plate
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Injection Mold-Hot Runner System
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Tooling considerations for product design.
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Plastic Design Major Messages
1. Maintain a uniform wall section - 2.0mm is typical. 2. Utilize the appropriate radii where applicable: 3. Strive to use snap fit and thread forming screws whenever possible to eliminate hardware, maximize design for assembly (DFA), and achieve the lowest cost Draft is mandatory. 1.5 degrees per side, plus 1 degree per depth of texture Eliminate side draws (slides) and undercuts (lifters) whenever possible. Use through wall openings Use the general tolerance box - tight tolerances drive up part and tooling cost Do not put datum on flexible walls or points in space. Plastic Design Major Messages
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Rib to Wall Ratio Typical Rules for Rib Thickness
Conventional Thermoplastics - 0.7T some sink mark will come - 0.4T for part which is visible Structural Foam T
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Uniform Wall Sections It is important to use uniform walls to minimize warp age and maximize manufacturability potential. Injection Molding : to 4mm Structural Foam : mm No thin areas less than 1.5mm No thick areas - core for uniform sections. Always try to core from the ejector side of part.
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Draft Angles Draft is needed to facilitate release of part from mold.
The draft to use, unless otherwise specified, is 1.5 degrees per side. Indicate if draft is to be added or subtracted from nominal dimension. Show draft on part whenever possible to avoid confusion as to direction. The "No Draft Allowed" is not to be used. Even on critical areas allow 0.5 degrees.
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Limits of Undercuts Eliminate undercuts by alternative redesign.
A minimum of 5 degree shut-off is required for all areas around a through opening. A 7 degree angle is even better. See "Bad" steel conditions for steel limitations
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"Bad" Steel Conditions Generally, "Bad" steel conditions can be avoided if all standing steel has a height to width ratio of 1:1 or better.
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Slide Core Molded Part Undercut Horn Pin Slide
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Slide Core
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Slide Core
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Slide Core Pulled Undercut
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Slide Core Pulled Undercut
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Slide Core
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Slide Core
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Slide Core
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Slide Core
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Slide Core
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Slide Core
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Slide Core Excessive travel
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Slide Core
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Slide Core Cover tool Molded part Horn Pin Locking Block Undercut
Spring Slide core
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Slide Core
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Slide Core
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Slide Core
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Slide Core
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Slide Core
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Slide Core
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Slide Core
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Slide Core Locking Block Core pin Molded part Horn Pin Undercut Spring
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Slide Core
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Slide Core
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Slide Core
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Slide Core
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Slide Core
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Slide Core
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Slide Core
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Slide Core
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Slide Core
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Accelerated Lifter Lifter Undercut Angled pin
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Accelerated Lifter
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Accelerated Lifter
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Accelerated Lifter
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Accelerated Lifter
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Accelerated Lifter
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Accelerated Lifter
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Accelerated Lifter Crash condition
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Hydraulic cylinder Core pin Undercut Hydraulic Cylinder
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Hydraulic cylinder
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Hydraulic pin
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Ejecting molded part
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Ejecting molded part
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Actuating Core pin
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Ejection of undercut part
Hydraulic Cylinder Slide Core
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Ejection of undercut part
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Ejection of undercut part
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Ejection of undercut part
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Ejection of undercut part
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Ejection of undercut part
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Ejection of undercut part
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Ejection of undercut part
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Ejection of undercut part
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Ejection of undercut part
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Pendulum Core Pin
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Pendulum Core Pin
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Pendulum Core Pin
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Pendulum Core Pin
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Pendulum Core Pin
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Pendulum Core Pin
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Pendulum Core Pin
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Pendulum Core Pin
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Pendulum Core Pin
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Pendulum Core Pin
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Center Rib with Undercut
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Center Rib with Undercut
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Center Rib with Undercut
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Center Rib with Undercut
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Center Rib with Undercut
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Center Rib with Undercut
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Center Rib with Undercut
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Forced Ejection
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Forced Ejection
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Forced Ejection
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Forced Ejection
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Forced Ejection
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Multiple Undercut Molded Part Slide Hydraulic Cylinder
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Die Opening
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Die Opening
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Lifter Ejection
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Part Ejection
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Lifter Return
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Slide Return
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Die Closing
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Multiple External Slides
Locking Block Core Pin Molded part Horn Pin Undercut Spring Slide
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Multiple External Slides
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Multiple External Slides
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Multiple External Slides
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Multiple External Slides
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Multiple External Slides
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Multiple External Slides
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Multiple External Slides
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Multiple External Slides
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Multiple External Slides
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Multiple Undercuts
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Multiple External Slides
Locking block Core pin Molded part Horn Pin Under Spring Slide
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Multiple External Slides
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Multiple External Slides
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Multiple External Slides
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Multiple External Slides
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Multiple External Slides
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Multiple External Slides
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Multiple External Slides
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Multiple External Slides
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Multiple External Slides
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Angled Lifter Molded part Lifter Undercut Horn pin Lose core
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Angled Lifter
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Ejection
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Ejection
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Ejection
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Ejection
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Die closing
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Die closing
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Die closing
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A B Impossible lifter condition B A
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Thanks
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Injection Mold-Hot Runner System
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