Product Design With Plastics

Plastic Product Design
Bhubaneswar Fomb
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
Product Design Environment
Product Design & Development Steps

1 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

1 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
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

4 CAD/CAE 1 2 Flow Analysis Stress Analysis
5
6
Prototype and Testing

End Use Testing
Polymer Fundamentals
INTRODUCTION
Plastics were considered as Replacing Materials

Todays 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.
CLASSIFICATION :
MATERIALS
Metals (as Ores) High-Molecular (Makromolecular) materails
Inorganic e.g. Glasses
Organic Natural e.g. Wood
Synthetic resp. Modified material
Thermoplastics
Thermosets
Elastomers
Thermoplastic elastomers
PLASTICS
Crosslinkable (vulcanisible) elastomers Crosslinked:rubber
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
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.
Acrylonitrile Butadiene Styrene Copolymer (ABS) :
Structure : amorphous
Density : 1,03 1,07 g/cm
Elastic-Modulus : ~ 2400 N/mm
Properties : High rigidity & toughness also at low temperature to 40 C, High Scratch resistance, High impact resistance, High suspectability to stress cracking Temperature limits: Short-Term ~ 100C, Long Term ~ 85C 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.
Acrylonitrile Butadiene Styrene Copolymer (ABS) : Applications
Polycarbonate (PC) :
Structure : amorphous Density : 1,20 1,24 g/cm Elastic-Modulus : ~ 2200 N/mm
Properties : High strength & Hardness, Toughness at low temperature. High impact resistance, High suspectability to stress cracking Temperature limits: Short-Term ~ 135C, Long Term ~ 100C 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.
Polycarbonate (PC) : Applications
Polyvinylchloride (PVC) :
Structure : amorphous Density : 1,38 1,55 g/cm Elastic-Modulus : ~ 3000 N/mm
Properties : High hardness & stiffness. High impact resistance at low temperature till -5C, below this brittleness increases. High suspectability to notch failure. Temperature limits: Short-Term ~ 70C, Long Term ~ 60C
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.
Polyvinylchloride (PVC) : Applications
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.
Polyethylene (PE) :
Structure : Semi crystalline N/mm Density : 0.91 0.96 g/cm Elastic-Modulus : ~ 1200
Properties : High stiffness & Hardness. Good elastic properties. Practically unbreakable, ductile till -60C Temperature limits: Short-Term ~ 135C, Long Term ~ 80C
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.
Polyethylene (PE) : Applications
Polypropylene (PP) :
Structure : Semi crystalline N/mm Density : 0.90 0.92 g/cm Elastic-Modulus : ~ 1450
Properties : High stiffness & Hardness. Stability higher than PE. High flexural fatigue strength. Low impact strength at low temperature. Temperature limits: Short-Term ~ 140C, Long Term ~ 100C
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.
Polypropylene (PP) : Applications
Polyamide (PA) :
Structure : Semi crystalline 2800 N/mm Density : 1.02 1.15 g/cm Elastic-Modulus : ~ 1300 -
Properties : High stiffness & impact strength. Good friction & wear resistance Temperature limits: Short-Term ~ 170C, Long Term ~ 110C
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.
Polyamide (PA) : Applications
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.
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.
Design Guidelines
REQUIREMENT
(For what ?, strength, assy)
MATERIAL SELECTION
(Cost , Manuf Prosess,Temp conds, Strength, Safety)
PACKAGING DATA & KINEMATICS
( From customer)
DECIDING SNAP & SCREW FIXING LOCATIONS FIX TOOLING DIRECTION
(Locking 6 deg. Of freedom, DFA )
(Die-Draw direction, Minimum silders and aesthetic requirement ) (Packaging data, strength requirement)
DECIDING STRENGTHING RIBS,LOCATIONS & GEOMETRY DRAFT ANGLES,RIBS WALL THICKNESS RATIO
(As per design guidelines)
Design Guidelines
TOOLING FEASIBILITY
( Minimum core thickness, Slider ejection space, Sharp corners etc.)
DRAFT ANALYSIS A & B SURFACES
SECTIONS WITH PACKAGING THROUGH SNAP & RIBS
( Tolerance issues)
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.
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.
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.
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 ASurface, 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.
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.
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.
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.
Design Guidelines
Bosses :
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.
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.
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.
Design Guidelines
Snap fit assembly :
Design Guidelines
Snap fit assembly :
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.
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.
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.
Bolts Nuts - Screws :
Design Guidelines
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.
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.
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:

1. 2. 3. 4. 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.
5.
TOLERANCE RANGE TO BE GIVEN ON DWGS:
HOW SLIDERS & LIFTERS WORK ?
SLIDER FOR UNDERCUT :
Molded Part
Horn Pin
Undercut
Slide
Pulled Undercut

Cover tool
Molded part Horn Pin
Locking Block
Undercut
Spring
Slide core
LIFTER FOR UNDERCUT :

Lifter
Undercut
Angled pin

Lifter
Molded part
Undercut
Horn pin
Lose core
HYDRAULIC CYLINDER FOR UNDERCUT :

Core pin Undercut
Hydraulic Cylinder
FORCED EJECTION :
FORCED EJECTION :
FORCED EJECTION :
FORCED EJECTION :
FORCED EJECTION :
MULTIPLE UNDERCUTS
Molded Part Slide
Hydraulic Cylinder
MULTIPLE UNDERCUTS
MULTIPLE UNDERCUTS
MULTIPLE UNDERCUTS
MULTIPLE SLIDERS:
Locking Block
Core Pin
Undercut
Spring
Slide
MULTIPLE SLIDERS:
MULTIPLE SLIDERS:
REFERENCES: Honeywell Injection Moulding Processing Guide (2002). Honeywell Design Soultions (2002).
JCI Plastics Training Manual.

Injection Moulding Design by Pye
THANK YOU

1 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) 2 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) 3 Design for Behavior overtime Creep : Time dependent Increasing Strain under constant stress
Stress Relaxation: Reduction of stress under constant strain

3 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

3 Design for appearance Sink Marks, weld lines, air traps, voids, streaks, delamination, jetting, gate marks etc
4
5 6 7
Design for precision

Design for moldability Design for Recyclability Design for automation
Part Application Requirement
Material Selection Process
Material Selection Process
Design Based Material Selection
Guidelines for Injection Molded Design
Plastic Processing
Plastic Processing
Plastic Processing-Injection Molding
Plastic Processing-IMD
Assembly Techniques for Plastic parts
Assembly Techniques Snap Fits
Snap fit cantilever beam type
Snap fit cylindrical Type
Factors for calculating cantilever beam for Snap fit
Mold Design For Snap Fits
Assembly Techniques Spin Welding
Assembly Techniques Ultrasonic Welding
Assembly Techniques Hot Plate Welding
Assembly Techniques Adhesive Bonding
Assembly Techniques Ultrasonic Insertion
Assembly Techniques Screw and Bosses
Assembly Techniques for Plastic parts
Injection Mold
Injection Mold
Injection Mold- Slider and Stripper Plate
Injection Mold- Stripper Plate
Injection Mold- Stripper Plate
Injection Mold-Hot Runner System
Tooling considerations for product design.
128
Design Major Messages 1. Maintain a Plastic 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.
4. Draft is mandatory. 1.5 degrees per side, plus 1 degree per 0.001 depth of texture.
5. Eliminate side draws (slides) and undercuts (lifters) whenever possible. Use through wall openings. 6. Use the general tolerance box - tight tolerances drive up part and tooling cost. 7. Do not put datum on flexible walls or points in space.
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 - 1.0T
Uniform Wall Sections

It is important to use uniform walls to minimize warp age and maximize manufacturability potential. Injection Molding : 2 to 4mm Structural Foam : 5 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.
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.
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
"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.
Slide Core
Molded Part
Horn Pin
Undercut
Slide
Slide Core
Slide Core
Slide Core
Pulled Undercut
Slide Core
Pulled Undercut
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Excessive travel
Slide Core
Slide Core
Cover tool
Locking Block
Undercut
Spring
Slide core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Locking Block Core pin
Undercut
Spring
Slide core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Accelerated Lifter
Lifter
Undercut
Angled pin
Accelerated Lifter
Accelerated Lifter
Accelerated Lifter
Accelerated Lifter
Accelerated Lifter
Accelerated Lifter
Accelerated Lifter
Crash condition
Hydraulic cylinder
Core pin
Undercut
Hydraulic Cylinder
Hydraulic cylinder
Hydraulic pin
Ejecting molded part
Ejecting molded part
Actuating Core pin
Ejection of undercut part

Undercut
Hydraulic Cylinder
Slide Core
Pendulum Core Pin
Pendulum Core Pin
Pendulum Core Pin
Pendulum Core Pin
Pendulum Core Pin
Pendulum Core Pin
Pendulum Core Pin
Pendulum Core Pin
Pendulum Core Pin
Pendulum Core Pin
Center Rib with Undercut

Undercut
Forced Ejection
Forced Ejection
Forced Ejection
Forced Ejection
Forced Ejection
Multiple Undercut
Molded Part Slide
Hydraulic Cylinder
Die Opening
Die Opening
Lifter Ejection
Part Ejection
Lifter Return
Slide Return
Die Closing
Multiple External Slides

Locking Block Core Pin
Undercut
Spring
Slide
Multiple Undercuts

Locking block Core pin
Under
Spring
Slide
Angled Lifter
Lifter Molded part
Undercut
Horn pin
Lose core
Angled Lifter
Ejection
Ejection
Ejection
Ejection
Die closing
Die closing
Die closing
B
Impossible lifter condition B
Thanks
Injection Mold-Hot Runner System

Product Design With Plastics

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Product Design With Plastics

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Plastic Product Design

Product Design Environment

Product Design & Development Steps

Product Design & Development Steps

a) Mechanical Properties used for essential component design calculations

Product Design & Development Steps

Prototype and Testing

Plastics were considered as Replacing Materials

- Low manufacturing costs, especially with injection moulding technology.

Inorganic e.g. Glasses

Organic Natural e.g. Wood

Synthetic resp. Modified material

Crosslinkable (vulcanisible) elastomers Crosslinked:rubber

Transparent (Exception) : Styrol copolymers with Butatein like ABS.

Acrylonitrile Butadiene Styrene Copolymer (ABS) :

Density : 1,03 1,07 g/cm

Elastic-Modulus : ~ 2400 N/mm

Acrylonitrile Butadiene Styrene Copolymer (ABS) : Applications

Polycarbonate (PC) : Applications

Polyvinylchloride (PVC) : Applications

Non transparent (translucent), naturally coloured good slip properties.

Due to higher shrinkage may form voids during cooling.

Polyethylene (PE) : Applications

Polypropylene (PP) : Applications

Polyamide (PA) : Applications

Examples: Epoxy (EP), Phenol-formaldehyde (PF), etc.

They are highly deformable Insoluble.

Examples: Natural Rubber (NR), Ethylen-Propylen rubber (EOM, EPDM), etc.

(For what ?, strength, assy)

(Cost , Manuf Prosess,Temp conds, Strength, Safety)

PACKAGING DATA & KINEMATICS

DECIDING SNAP & SCREW FIXING LOCATIONS FIX TOOLING DIRECTION

(Locking 6 deg. Of freedom, DFA )

(As per design guidelines)

DRAFT ANALYSIS A & B SURFACES

SECTIONS WITH PACKAGING THROUGH SNAP & RIBS

Some important points to consider while rib design.

Molded-in Assembly : (Snap fit, Press fit, molded in threads etc.)

Y = Deflection Q values to be referred from Material graphs

Important points to remember :

Bolts Nuts - Screws :

General Guidelines while using self-tapping fasteners:

TOLERANCE RANGE TO BE GIVEN ON DWGS:

HOW SLIDERS & LIFTERS WORK ?

SLIDER FOR UNDERCUT :

SLIDER FOR UNDERCUT :

SLIDER FOR UNDERCUT :

SLIDER FOR UNDERCUT :

Molded part Horn Pin

SLIDER FOR UNDERCUT :

SLIDER FOR UNDERCUT :

SLIDER FOR UNDERCUT :

LIFTER FOR UNDERCUT :

LIFTER FOR UNDERCUT :

LIFTER FOR UNDERCUT :

LIFTER FOR UNDERCUT :

LIFTER FOR UNDERCUT :

LIFTER FOR UNDERCUT :

LIFTER FOR UNDERCUT :

HYDRAULIC CYLINDER FOR UNDERCUT :

HYDRAULIC CYLINDER FOR UNDERCUT :

HYDRAULIC CYLINDER FOR UNDERCUT :

Molded Part Slide

Molded part Horn Pin