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http://www.quickparts.com/learningcenter/basicsofinjectionmoldingdesign.aspx

Basics of Injection Molding Design

Designing plastic parts is a complex task involving many factors that address a list of requirements
of the application. How is the part to be used? How does it fit to other parts in the assembly?
What loads will it experience in use? In addition to functional and structural issues, processing
issues play a large role in the design of an injection molded plastic part. How the molten plastic
enters, fills, and cools within the cavity to form the part largely drives what form the features in that
part must take. Adhering to some basic rules of injection molded part design will result in a part
that, in addition to being easier to manufacture and assemble, will typically be much stronger in
service. Dividing a part into basic groups will help you to build your part in a logical manner while
minimizing molding problems. As a part is developed, always keep in mind how the part is molded
and what you can do to minimize stress.

Table of Contents

(a) Applications
(b) Polymers Best Suited for Injection Molding
(c) Injection Molding Equipment
(d) Injection Molding Process
(e) Injection Molding Cycle
(f) Different Types of Injection Molding Processes
(g) Stress
(h) Gates
(i) Common Gates
(j) Gate Location
(k) Wall Thickness
(l) Draft
(m) Sink Marks
(n) Textures
(o) Parting Lines
(p) Common Molding Defects

(a) Applications

Plastic injection molding is the preferred process for manufacturing plastic parts. Injection molding
is used to create many things such as electronic housings, containers, bottle caps, automotive
interiors, combs, and most other plastic products available today. It is ideal for producing high
volumes of plastic parts due to the fact that several parts can be produced in each cycle by using
multi-cavity injection molds. Some advantages of injection molding are high tolerance precision,
repeatability, large material selection, low labor cost, minimal scrap losses, and little need to finish
parts after molding. Some disadvantages of this process are expensive upfront tooling investment
and process limitations.

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(b) Polymers Best Suited for Injection Molding

Most polymers may be used, including all thermoplastics, some thermosets, and some elastomers.
There are tens of thousands of different materials available for injection molding. The available
materials mixed with alloys or blends of previously developed materials means that product
designers can choose from a vast selection of materials to find the one that has exactly the right
properties. Materials are chosen based on the strength and function required for the final part; but
also each material has different parameters for molding that must be considered. Common polymers
like Epoxy and phenolic are examples of thermosetting plastics while nylon, polyethylene, and
polystyrene are thermoplastic.


(c) Injection Molding Equipment

Injection Molding Machine:

Injection molding machines, also known as presses, consist of a material hopper, an injection ram or
screw-type plunger, and a heating unit. Molds are clamped to the platen of the molding machine,
where plastic is injected into the mold through the sprue orifice. Presses are rated by tonnage, which
is the calculation of the amount of clamping force that the machine can exert. This force keeps the
mold closed during the injection molding process. Tonnage can vary from less than 5 tons to 6,000
tons, although the higher tonnage presses are rarely used. The total clamp force needed is
determined by the projected area of the custom part being molded. This projected area is multiplied
by a clamp force of from 2 to 8 tons for each square inch of the projected areas. As a rule of thumb,
4 or 5 tons/in can be used for most products. If the plastic material is very stiff, it will require more
injection pressure to fill the mold, thus more clamp tonnage is needed to hold the mold closed. The
required force can also be determined by the material used and the size of the part with larger
plastic parts requiring higher clamping force.

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Mold:

The mold or die refers to the tooling used to produce plastic parts in molding. Traditionally
injection molds have been expensive to manufacture and were only used in high-volume production
applications where thousands of parts were produced. Molds are typically constructed from
hardened steel, pre-hardened steel, aluminum, and/or beryllium-copper alloy. The choice of material
to build a mold from is primarily one of economics. Steel molds generally cost more to construct
but offer a longer lifespan that will offset the higher initial cost over a higher number of parts made
before wearing out. Pre-hardened steel molds are less wear resistant and are primarilly used for
lower volume requirements or larger components. The hardness of the pre-hardened steel measures
typically 38-45 on the Rockwell-C scale. Hardened steel molds are heat treated after machining,
making them superior in terms of wear resistance and lifespan. Typical hardness ranges between 50
and 60 Rockwell-C (HRC).
Aluminum molds cost substantially less than steel molds, and when higher grade aluminum such as
QC-7 and QC-10 aircraft aluminum is used and machined with modern computerized equipment,
they can be economical for molding hundreds of thousands of parts. Aluminum molds also offer
quick turnaround and faster cycles because of better heat dissipation. They can also be coated for
wear resistance to fiberglass reinforced materials. Beryllium copper is used in areas of the mold
which require fast heat removal or areas that see the most shear heat generated.

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(d) Injection Molding Process

With injection molding, granular plastic is fed by gravity from a hopper into a heated barrel. As the
granules are slowly pushed forward by a screw-type plunger, the plastic is forced into a heated
chamber called the barrel where it is melted. As the plunger advances, the melted plastic is forced
through a nozzle that seats against the mold sprue bushing, allowing it to enter the mold cavity
through a gate and runner system. The mold remains at a set temperature so the plastic can solidify
almost as soon as the mold is filled.



(e) Injection Molding Cycle

The sequence of events during the injection molding of a plastic part is called the injection molding
cycle. The cycle begins when the mold closes, followed by the injection of the polymer into the
mold cavity. Once the cavity is filled, a holding pressure is maintained to compensate for material
shrinkage. In the next step, the screw turns, feeding the next shot to the front screw. This causes the
screw to retract as the next shot is prepared. Once the part is sufficiently cool, the mold opens and
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the part is ejected.



(f) Different Types of Injection Molding Processes

Although most injection molding processes are covered by the conventional process description
above, there are several important molding variations including:
Co-injection(sandwich)molding
Fusible(lost, soluble)core injection molding
Gas-assisted injection molding
In-mold decoration and in mold lamination
Injection-compression molding
Injection molding of liquid silicone rubber
Insert and outsert molding
Lamellar (microlayer) injection molding
Low-pressure injection molding
Microinjection molding
Microcellular molding
Multicomponent injection molding(overmolding)
Multiple live-feed injection molding
Powder injection molding
Push-Pull injection molding
Reaction injection molding
Resin transfer molding
Rheomolding
Structural foam injection molding
Structural reaction injection molding
Thin-wall molding
Vibration gas injection molding
Water assisted injection molding
Rubber injection


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(g) Stress

The main enemy of any injection molded plastic part is stress. When a plastic resin (which contains
long strains of molecules) is melted in preparation for molding, the molecular bonds are temporarily
broken due to the heat and shear force of the extruder, allowing the molecules to flow into the mold.
Using pressure, the resin is forced into the mold filling in every feature, crack and crevice of the
mold. As the molecules are pushed through each feature, they are forced to bend, turn and distort to
form the shape of the part. Turning hard or sharp corners exerts more stress on the molecule than
taking gentle turns with generous radii. Abrupt transitions from one feature to another are also
difficult for the molecules to fill and form to. As the material cools and the molecular bonds re-link
the resin into its rigid form, these stresses are in effect locked into the part. Part stresses can cause
warpage, sink marks, cracking, premature failure and other problems. While some stresses in an
injection molded part are to be expected, you should design your parts with as much consideration
for stress reduction as possible. Some ways to do this are by adding smooth transitions between
features and using rounds and fillets in possible high stress areas.



(h) Gates

Each injection mold design must have a gate, or an opening that allows the molten plastic to be
injected into the cavity of the mold. Gate type, design and location can have effects on the part such
as part packing, gate removal or vestige, cosmetic appearance of the part, and part dimensions &
warping.


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Gate Types

There are two types of gates available for injection molding; manually trimmed and automatically
trimmed gates.

Manually Trimmed Gates:

These type of gates require an operator to separate the aprts from the runners manually after each
cycle. Manually trimmed gates are chosen for several reasons:
The gate is too bulky to be automatically sheared by the machine
Shear-sensitive materials such as PVC cannot be exposed to high shear rates
Flow distribution for certain designs that require simultaneous flow distribution across a
wide front
Automatically Trimmed Gates

These type of gates incorporate features in the tool to break or shear the gates when the tool opens
to eject the part. Automatically trimmed gates are used for several reasons:
Avoiding gate removal as a secondary operation, reducing cost
Maintaining consistent cycle times for all parts
Minimizing gate scars on parts


(i) Common Gates

The largest factor to consider when choosing the proper gate type for your application is the gate
design. There are many different gate designs available based on the size and shape of your part.
Below are four of the most popular gate designs used by Quickparts customers:

The Edge Gate is the most common gate design. As the name indicates, this gate is located on the
edge of the part and is best suited for flat parts. Edge gates are ideal for medium and thick sections
and can be used on multicavity two plate tools. This gate will leave a scar at the parting line.

The Sub Gate is the only automatically trimmed gate on the list. Ejector pins will be necessary for
automatic trimming of this gate. Sub gates are quite common and have several variations such as
banana gate, tunnel gate and smiley gate to name a few. The sub gate allows you to gate away from
the parting line, giving more flexibility to place the gate at an optimum location on the part. This
gate leaves a pin sized scar on the part.

The Hot Tip Gate is the most common of all hot runner gates. Hot tip gates are typically located at
the top of the part rather than on the parting line and are ideal for round or conical shapes where
uniform flow is necessary. This gate leaves a small raised nub on the surface of the part. Hot tip
gates are only used with hot runner molding systems. This means that, unlike cold runner systems,
the plastic is ejected into the mold through a heated nozzle and then cooled to the proper thickness
and shape in the mold.

The Direct or Sprue Gate is a manually trimmed gate that is used for single cavity molds of large
cylindrical parts that require symmetrical filling. Direct gates are the easiest to design and have low
cost and maintenance requirements. Direct gated parts are typically lower stressed and provide high
strength. This gate leaves a large scar on the part at the point of contact.
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(j) Gate Location

To avoid problems from your gate location, below are some guidelines for choosing the proper gate
location(s):
Place gates at the heaviest cross section to allow for part packing and minimize voids &
sink.
Minimize obstructions in the flow path by placing gates away from cores & pins.
Be sure that stress from the gate is in an area that will not affect part function or aesthetics.
If you are using a plastic with a high shrink grade, the part may shrink near the gate
causing gate pucker if there is high molded-in stress at the gate
Be sure to allow for easy manual or automatic degating.
Gate should minimize flow path length to avoid cosmetic flow marks.
In some cases, it may be necessary to add a second gate to properly fill the parts.
If filling problems occur with thin walled parts, add flow channels or make wall thickness
adjustments to correct the flow.
Gates vary in size and shape depending upon the type of plastic being molded and the size of the
part. Large parts will require larger gates to provide a bigger flow of resin to shorten the mold time.
Small gates have a better appearance but take longer time to mold or may need to have higher
pressure to fill correctly.





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(k) Wall Thickness

Prior to ejection from the mold, injection molded parts are cooled down from manufacturing
temperatures so that they hold their shape when ejected. During the part cooling step of the molding
process, changes in pressure, velocity and plastic viscosity should be minimized to avoid defects.
Few aspects are more crucial during this period than wall thickness. This feature can have major
effects on the cost, production speed and quality of the final parts.

Proper Wall Thickness:

Choosing the proper wall thickness for your part can have drastic effects on the cost and production
speed of manufacturing. While there are no wall thickness restrictions, the goal is usually to choose
the thinnest wall possible. Thinner walls use less material which reduces cost and take less time to
cool, reducing cycle time.



The minimum wall thickness that can be used depends on the size and geometry of the part,
structural requirements, and flow behavior of the resin. The wall thicknesses of an injection molded
part generally range from 2mm 4mm (0.080 0.160). Thin wall injection molding can produce
walls as thin as 0.5mm (0.020). The chart below shows recommended wall thicknesses for
common injection molding resins.

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(l) Draft

Most injection molded plastic parts include features such as outside walls and internal ribs that are
formed by opposing surfaces of tool metal inside a closed mold. To properly release the part when
the mold opens, the side walls of the mold are tapered in the direction that the mold opens. This
tapering is referred to as draft in the line of draw. This draft allows the part to break free of the
mold as soon as the mold opens. The amount of draft required can depend on the surface finish of
the mold. A smooth, polished tool surface will allow the part to eject with less draft than a standard
tool surface. Consider the fabrication of the hollow plastic box seen to the right. Once the plastic
has hardened around the mold, the mold must be removed. As the plastic hardens, it will contract
slightly. By tapering the sides of the mold by an appropriate "draft angle", the mold will be easier to
remove. The amount of draft required (in degrees) will vary with geometry and surface texture
requirements of the part. Below are several rules for using draft properly:
Be sure to add draft to your 3D CAD model before creating radii
Use at least 1 degree of draft on all "vertical" faces
1 degrees of draft is required for light texture
2 degrees of draft works very well in most situations
3 degrees of draft is a minimum for a shutoff (metal sliding on metal)
3 degrees of draft is required for medium texture
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(m) Sink Marks

When the hot melt flows into the injection mold, the thick sections dont cool as fast as the rest of
the part because the thicker material becomes insulated by the outside surface of faster cooling
plastic. As the inner core cools, it shrinks at a different rate than the already cooled outer skin. This
difference on cooling rates causes the thick section to draw inward and create a sink mark on the
outside surface of the part, or worse, completely warp the part. In addition to being unattractive, the
mark also represents added stress that is built into the part. Other less conspicuous areas where sink
occurs include ribs, bosses and corners. These are often overlooked because neither the feature nor
the part itself is too thick; however, the intersection of the two can be a problem. One way to avoid
sink marks is to core out the solid sections of the part to reduce thick areas. If the strength of a solid
part is required, try using cross hatched rib patterns inside the cored out area to increase strength
and avoid sink. As a rule-of-thumb, make sure that all bosses and locating/support ribs are no more
than 60% of the thickness of the nominal wall. Also, textures can be used to hide minor sink marks.

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(n) Textures

Texturing is a process used to apply patterns to a mold surface. This process allows flexibility in
creating the final appearance of your parts. Texturing is an integral piece in overall product
development and should be considered during the design process to achieve the desired results.
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Texture can be a functional component of design as well. Imperfect parts can be camouflaged by the
right texture. Is the part designed for frequent handling? Texture can be used to hide finger prints
and improve the grip for the end user. Texture can also be used to reduce part wear from friction.
A wide variety of textures are available for injection molded parts such as:

Natural/Exotic
Matte Finishes
Multi-Gloss Patterns
Fusions
Graphics
Leather Grains/Hides
Woodgrain, Slate & Cobblestone
Geometric & Linens
Layered Textures to Create New Looks
Images or Logos Incorporated into the Pattern



When applying a texture to a part, the CAD drawing must be adjusted to accommodate for this
surface variance. If the texture is on a surface that is perpendicular or angled away from the mold
opening then no draft changes are necessary. If the texture is on a parallel surface with the mold
opening, however, increased draft is necessary to prevent scraping and drag marks that could occur
during part ejection. Different textures have different impacts on the molded part. The rule-of-
thumb when designing for texture is to have 1.5 degrees of draft for each 0.001 of texture finish
depth.

(o) Parting Lines

A parting line is the line of separation on the part where the two halves of the mold meet. The line
actually indicates the parting plane that passes through the part. While on simple parts this plane
can be a simple, flat surface, it is often a complex form that traces the perimeter of the part around
the various features that make up the parts outer silhouette. Part lines can also occur where any
two pieces of a mold meet. This can include side action pins, tool inserts and shutoffs. Parting lines
cannot be avoided; every part has them. Keep in mind when designing your part, that the melt will
always flow towards the parting line because it is the easiest place for the displaced air to escape or
vent

(p) Common Molding Defects

Injection molding is a complex technology with possible production problems. They can either be
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caused by defects in the molds or more often by part processing (molding)

Molding
Defects
Alternative
Name
Descriptions Causes
Blister Blistering
Raised or layered zone
on surface of the
Plastic part
Tool or material is too hot, often caused by
a lack of cooling around the tool or a faulty
heater
Burn marks
Air Burn/Gas
Burn
Black or brown burnt
areas on the plastic
part located at furthest
points from gate
Tool lacks venting, injection speed is too
high
Color streaks
(US)

Localized change of
color
Plastic material and colorant isn't mixing
properly, or the material has run out and it's
starting to come through as natural only
Delamination
Thin mica like layers
formed in part wall
Contamination of the material e.g. PP
mixed with ABS, very dangerous if the part
is being used for a safety critical
application as the material has very little
strength when delaminated as the materials
cannot bond
Flash Burrs
Excess material in thin
layer exceeding
normal part geometry
Tool damage, too much injection
speed/material injected, clamping force too
low. Can also be caused by dirt and
contaminants around tooling surfaces.
Embedded
contaminates
Embedded
particulates
Foreign particle (burnt
material or other)
embedded in the part
Particles on the tool surface, contaminated
material or foreign debris in the barrel, or
too much shear heat burning the material
prior to injection
Flow marks Flow lines
Directionally "off
tone" wavy lines or
patterns
Injection speeds too slow (the plastic has
cooled down too much during injection,
injection speeds must be set as fast as you
can get away with at all times)
J etting

Deformed part by
turbulent flow of
material
Poor tool design, gate position or runner.
Injection speed set too high.
Polymer
degradation

polymer breakdown
from oxidation, etc.
Excess water in the granules, excessive
temperatures in barrel
Sink marks
Localized depression
(In thicker zones)
Holding time/pressure too low, cooling
time too short, with sprueless hot runners
this can also be caused by the gate
temperature being set too high
Short shot
Non-Fill/Short
Mold
Partial part
Lack of material, injection speed or
pressure too low
Splay marks
Splash
Mark/Silver
Streaks
Circular pattern around
gate caused by hot gas
Moisture in the material, usually when
resins are dried improperly
Stringiness Stringing
String like remain
from previous shot
transfer in new shot
Nozzle temperature too high. Gate hasn't
frozen off
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Voids
Empty space within
part
(Air pocket)
Lack of holding pressure (holding pressure
is used to pack out the part during the
holding time). Also mold may be out of
registration (when the two halves don't
center properly and part walls are not the
same thickness).
Weld line
Knit
Line/Meld
Line
Discolored line where
two flow fronts meet
Mold/material temperatures set too low (the
material is cold when they meet, so they
don't bond)
Warping Twisting Part Distorted part
Cooling is too short, material is too hot,
lack of cooling around the tool, incorrect
water temperatures (the parts bow inwards
towards the hot side of the tool)


Keep these factors in mind when designing your injection molded part, and remember that it is
easier to avoid problems in the beginning than change your design down the line.