Plastics

Thermoplastics Thermosets

Crystalline Commodity

Semi crystalline Engineering

Amorphous Specialty plastics

Plastic Generic Families
Acetal (Acetal)
Acrylic (Acrylic)
Acrylonitrile Butadiene Styrene (ABS)
Acrylonitrile Ethylene Styrene (AES)
Acrylonitrile Styrene (AS)
Acrylonitrile Styrene Acrylate (ASA)
Alkyd (Alkyd)
Alphamethylstyrene (AMS)
Biodegradable Polymers (Biodeg Polymers)
Cellulose Acetate (CA)
Diallyl Phthalate (DAP)
Dicyclopentadiene (DCPD)
Epoxy (Epoxy)
Fluoropolymer (Fluoropolymer)
Furan (Furan)
Ionomer (Ionomer)
Liquid Crystal Polymer (LCP)
Maleic Anhydride Grafted Polymer (MAH-g)
Melamine (Melamine)
Methyl Cellulose (MC)
Methyl Methacrylate (MM)
Phenolic (Phenolic)
Polyamide (Nylon)
Polyarylate (Polyarylate)
Polybenzimidazole (PBI)
Polybutadiene Rubber (PBR)
Polybutylene (PB)
Polycaprolactone (PCL)
Polycarbonate (PC)
Polyester (Polyester)
Polyether Imide (PEI)
Polyetherketone (PEK)
Polyethylene (PE)
Polyethylene Naphthalate (PEN)
Polyimide (PI)
Polyketone (PK)
Polylactic Acid (PLA)
Polymethylpentene (PMP)
Polyolefin (Polyolefin)
Polyparaxylylene (PPX)
Polyphenylene Ether (PPE)
Polyphenylene Sulfide (PPS)
Polypropylene (PP)
Polystyrene (PS)
Polysulfone (PSU)
Polyurethane (PUR)
Polyurethane Thermoset Elastomer (TSU)
Polyvinyl Chloride (PVC)
Proprietary (Proprietary)
Silicone (Silicone)
Styrene Acrylonitrile (SAN)
Styrene Acrylonitrile Silicone (SAS)
Styrene Maleic Anhydride (SMA)
Styrenic + Vinyl + Acrylonitrile (SVA)
Thermoplastic Elastomer (TPE)
Thermoplastic Polyurethane (TPU)
Thermoplastic, Unspecified (TP, Unspecified)
Thermoset (TS)
Thermoset Elastomer (TSE)
Unspecified (Unspecified)
Urea (Urea)
Vinyl Alcohol (VOH)
Various Thermoplastics

PI
Specialty Polymers
PSU PTFE
LCP
PES
PPSU PPA
PA
Engineering Polymers PC POM
PET
PPO PBT
TPE
ABS PMMA
Commodities PS
PP-GF PE-UHMW
PVC
PP PE-HD
SAN PE-LD

AMORPHOUS CRYSTALLINE
 Material Strengths

• Amorphous • Semi-Crystalline
– Impact Resistance – Lower Melt Viscosity
– Clarity – Wear Properties
– Close Tolerances – Chemical Resistance
– Resistance to Warp – Fatigue Resistance
– Stress Crack Resistance
– Benefit from Reinforcement

Blends Can Help Split the Difference

 FRP Materials & Manufacturing Process

Resins Reinforcements
• Epoxy resin • Glass Fiber
• Phenolics • Kevlar
• Polyester • Carbon fiber
• Vinylester • Aramid
• Cyanate esters • Natural fiber
• Bismaleimide
• Polyimide
• Poly urethane
• Poly Propylene
• Nylon
• PEEK
• PPS
Advantages

Disadvantages
• Properties can be altered to suit • Surface hardness
our needs • Electrical conductivity
• Good strength to weight ratio • High temperature
• Tough & durable • Thermal expansion
• Non toxic
• Easy process ability
• Chemical resistant
• Fire retardant
• Vibration damping
• Integral design
• Corrosion resistant
• Attractive colors
• Good weather ability
• Maintenance free
• Reusable/Recyclable
• Cost
The use of various additives to extend the capabilities of the plastic base
material.

• Short glass fibers can strengthen a resin and help prevent high-temperature creep.
They can, however, make a resin more brittle and increase the tendency to warp as a
part cools.
• Long glass fibers provide greater strength and creep resistance, but can impede resin
flow, particularly through thin areas.
• Aramid (Kevlar®) fibers add strength, though not as much as glass, and are less
abrasive than glass.
• Carbon fiber can strengthen and stiffen a resin and aid in static dissipation, but is
costly and can lead to warp.
• Stainless steel fibers are used in electrical housings to reduce electromagnetic and
radio frequency interference.
• Mineral fillers—talc or clay—can increase hardness and reduce both cost and warp.
• Glass beads and mica flakes add stiffness and reduce warp and shrinkage, but can
be challenging to inject.
• PTFE (Teflon®) and molybdenum disulfide, dry lubricants that function like
graphite, can make plastic parts self-lubricating.
• UV inhibitors help prevent material breakdown in outdoor applications.
How to select a material ?
The basic properties that should be considered during material selection
Glass transition: The reversible change in an amorphous polymer or in amorphous
regions of a partially crystalline polymer from (or to) a viscous or rubbery condition to
(or from) a hard and relatively brittle one. The glass transition generally occurs over a
relatively narrow temperature region. Not only do hardness and brittleness undergo
rapid changes in this temperature region, but also other properties, such as thermal
expansion and specific heat, change rapidly. The glass transition temperature range is
generally provided by material suppliers on their data sheets.
Heat deflection temperature: The temperature at which a standard test specimen
deflects 0.010 inch under a stated load of either 66 or 264 psi. This temperature is one
indicator of how a resin might behave at elevated temperatures.
Impact resistance: Relative susceptibility of plastics to fracture by shock—e.g., as
indicated by the energy expended by a standard pendulum-type impact machine in
breaking a standard specimen in one blow. The most common type of test is Izod
impact (see below).
Izod impact: A test designed to determine the resistance of a plastic material to a shock
loading. It involves the notching of a specimen, which is then placed in the jaws of a
machine and struck with a weighted pendulum.
Tensile strength: The pulling force per area required to yield or break a given
specimen. The area used in computing strength is usually the original, rather than the
necked-down area.
Toughness: The resistance to fracture of a plastic when stressed.
Product design can be defined as the systematic approach of idea generation,
concept development, prototype, testing and manufacturing or implementation.

BASIC CONCEPTS OF DESIGN

Size Shape Function

Aesthetics Quality Cost

 Methodical approach in Plastics Product Design

1 • Define the function of the part with life requirement

2 • State the load limitations of the part

3 • Define all the environmental stress that the part will be exposed to its intended functions

4 • Select several materials that appear to meet the requirements

5 • Go for multiple design solutions for different materials to perform the required function

6 • Determine the appropriate manufacturing process for each design

7 • Evaluate the costs of different design solutions

8 • Select the probable part design, material and manufacturing process

9 • Do FEM analysis to check the effectiveness of the part

10 • Build prototype tooling

11 • Make prototype part and test parts to determine if they meet the required functions

12 • Redesign the part if necessary based on the prototype testing

13 • Retest the part again

14 • Make field tests

15 • Take the part for implementation

 In order to design plastic components for product ability, the following
guidelines should be observed:
1. Small holes (less than 1.5 mm diameter) should be drilled after molding.
2. Molded blind holes should be limited in depth to twice their diameter
3. All holes should be located perpendicular to the parting line to allow easy
removal of the part from the mold.
4. Undercuts should be avoided, since they require a more costly mold. The mold
must either be split or have a removable core section.
5. The distance between adjacent holes should be greater than 5 mm.
6. The height of bosses should be less than twice their diameter.
7. In the design of bosses, taper of at least 1o on each side should be incorporated
to assure easy withdrawal from the mould.
8. Radii at both the top and the base should be included in design of bosses and
ribs. These radii should not be less than 0.8mm.
9. Ribs should be designed with 2o to 5o taper on each side and rib width at the
base should be at least 1 ½ times the wall thickness, the height should be
limited to 1 ½ times the wall thickness.
10. At the parting line, outside edges should be designed without a radius.
11. The design should permit both ends of inserts to be supported in the
mould.
12. Inserts should be at right angles to the parting line.
13. A taper 1o to 2o should be specified on those vertical surfaces parallel with
the direction of mold surfaces.
14. Concave numbers and lettering should be engraved in the mould. Letters
should be approximately 2.5mm high and 0.15mm in deep.
15. Threads that are less than 7.5mm in diameter should be drilled after
moulding.
16. Maintaining uniform and nominal wall thickness.
 Thermoplastic Minimum mm Average mm Maximum
material mm

Acetal 0.4 .1.6 3.2

ABS 0.8 2.3 3.2
Acrylic 0.6 2.4 6.4
Wall thickness

Cellulosics 0.7 1.9 4.8

FEP fluoroplastic 0.3 9.0 12.7
Nylon 0.4 1.6 4.0
Polycarbonate 1.0 2.4 10.0
Polyethylene (L.D.) 0.5 1.6 6.4
Polyethylene (H.D) 0.9 1.6 6.4
Ethylene vinyl acetate 0.5 1.6 3.2
Polypropylene 0.6 2.0 7.6
Polysulfone 1.0 2.6 9.5
Noryl (modified PPO) 0.8 2.0 9.5
Polystyrene 0.8 1.6 6.4
SAN 0.8 1.6 6.4
PVC-rigid 1.0 2.4 9.5
Polyurethane 0.7 12.7 38.0
Surlyn (ionomer) 0.7 1.6 19.0
Thermosetting materials Minimum Average Maximum
Thickness Thickness Thickness
mm mm mm

Alkyd-glass filled 1.0 3.2 12.7

Alkyd-mineral filled 1.0 4.8 9.5
Diallyl Phthalate 1.0 4.8 9.5
Epoxy 0.8 3.2 25.4
Melamine-cellulose filled 0.9 2.5 4.8
Urea-cellulose filled 0.9 2.5 4.8
Phenolic-general purpose 1.3 3.2 25.4
Phenolic-flock filled 1.3 3.2 25.4
Phenolic-glass filled 0.8 2.4 19.0
Phenolic-fabric filled 1.6 4.8 9.5
Phenolic-mineral filled 3.2 4.8 25.4
Silicon glass 1.3 3.2 6.4
Polyester premix 1.0 1.8 25.4
Defining requirements

Mechanical Loading - all types of mechanical loading including short-term static

loads, impacts, and vibrational or cyclic loads that could lead to fatigue

Temperature - Many material properties in plastics — impact strength, modulus,

tensile strength, and creep resistance to name a few — vary with temperature

Chemical Exposure - Plastic parts encounter a wide variety of chemicals both

during manufacturing and in the end-use environment

Electrical Performance - Note required electrical property values and nature of

electrical loading (conductivity, dielectric strength, dielectric constant loss factor,
and surface tracking)

Weather Resistance - Temperature, moisture, and UV sun exposure affect plastic

parts’ properties and appearance

Radiation - A variety of artificial sources — such as fluorescent lights, high-

intensity discharge lamps, and gamma sterilization units — emit radiation that can
yellow and/or degrade many plastics
Appearance

Life Expectancy - Determine a reasonable life expectancy for your part

Dimensional Tolerances - Many applications have features requiring tight

tolerances for proper fit and function. Consider the effect of load, temperature,
and creep on dimensions. Over-specification of tolerance can increase product
cost significantly.

Production Quantities

Processing

Cost Constraints
 Principles & Concepts in Plastic Product Design
Successful manufacture of good plastic products required a combination of
sound judgement and experience. Design of a good plastic product
requires knowledge of plastics & their properties, various moulding
methods, post moulding procedures and information on key design areas.

Wall thickness - Parting line

Ribs - bosses
Fillets, radius & gussets
Draft - Holes - Coring
Gate size & location – Ejector pins
Tolerance – Undercuts – Metal inserts
Threads – Surface finish - Shrinkage
1. Wall thickness

Maintain uniform nominal wall thickness.

Avoid wall thickness variations that result in filling from thin to thick
sections
Wall thickness strongly influences many key part characteristics, including
mechanical performance and feel, cosmetic appearance, moldability, and
economy.
The optimum thickness is often a balance between opposing tendencies,
such as strength versus weight reduction or durability versus cost.

Stiffening Profiles for Edges

Thickness Transitions - Blend transitions
to minimize read-through
2. Parting line

A mold consists of two main parts: the cavity and core. The core forms the
main internal surfaces of the part. The cavity forms the major external surfaces.
Typically, the core and cavity separate as the mold opens, so that the part can be
removed. This mold separation occurs along the interface known as the
parting line.
Note: - Choose the parting-line location to minimize undercuts that would
hinder or prevent easy part removal
Components of a standard two-plate mold base with two cavities
3. Ribs and Bosses
Ribs provide a means to economically augment
stiffness and strength in molded parts without
increasing overall wall thickness.
Locating and captivating components of an
assembly
Sink opposite thick rib
Providing alignment in mating parts
Acting as stops or guides for mechanisms

Offsetting the rib

 Use buttress ribs to stiffen side walls

Replace large problematic ribs with

multiple shorter ribs
Warpage vs. Rib Thickness
BOSSES
Bosses find use in many part designs as points for attachment and assembly.
The most common variety consists of cylindrical projections with holes
designed to receive screws, threaded inserts, or other types of fastening
hardware

Boss Design Connecting bosses to walls

4. Fillets, Radii and Gussets

Sharp corners should be avoided

They are the number one cause of part failure, stress concentrations, poor
flow patterns and increased tool wear
Indicate radii at all inside and outside corners to the maximum which a
design will allow
GUSSETS
Gussets are rib-like features that add support to structures such as bosses, ribs, and
walls

Gussets
5. Draft

Draft is necessary for the ejection of

the parts from the mold
Draft is providing angles or tapers on
product features such as walls, ribs,
posts, and bosses that lie parallel to
the direction of release from the mold
— eases part ejection
Use the standard one degree of draft
plus one additional degree of draft for
every 0.001 inch of texture depth as a
rule of thumb

Draft
6. Holes

Holes are easily produced in molded parts by core pins.

Cores are the protruding parts of the mold that form the inside surfaces
of features such as holes, pockets, and recesses

The ends of the long cores should interlock into

mating surfaces for support
7. Coring

Cores also remove plastic from thick

areas to maintain a uniform wall
thickness
For simplicity and economical reason
coring should be done parallel to the
mold opening direction

Coring out the thicker sections

8. Gate size & location

The gate connects the part to the runner system. It is usually the thinnest cross-
section in the entire system. The design of the gate is dependent on tool design,
part geometry and the material selection.
Gates should be located away from high stress or impact areas.
Gate configuration and location should minimally affect part appearance.
Gate design and location should eliminate secondary degating operations if
possible.
The gate should be located to best fill the part; position flow for advantageous
glass fiber orientation if present and locate knit lines in low-stress areas.

Sprue gate
 Edge gate Tab gate

Film gate
Overlapping gate
 Ring gate (Inner) Spoke gate

Ring gate (outer) Pin point gate

Tunnel / submarine gate Hot tip gate Hot valve gate

Typical gate thickness for different wall thickness

9. Location of Ejector pins

The method of ejection has to be adapted to the shape of the molding to prevent
damage.
The mold release is hindered by shrinkage of the part on the mold cores
Large ejection areas uniformly distributed over the molding are advised to avoid
deformations.
The types of ejections are
Pin
Sleeve
Blade
Stripper plate
Air
10. Tolerance

Establishing the correct tolerances with respect to the product function is of

economical importance.
The designer should be aware that dimensions with tight tolerances have a big
influence on the costs of both the product and the tool.
It is recommended to indicate only critical dimensions with tolerances on the
drawing.

Depending on the application, a division into three tolerance classes can be made
Normal; price index 100
Accurate, technical injection molding; price index 170
Precise, precision injection molding: price index 300
Characteristics of tolerance classes

Factors affecting tolerances

11. Undercuts

Some design features, because of their

orientation, place portions of the mold in the way
of the ejecting plastic part. Called “undercuts,”
these elements can be difficult to redesign.

Stripping Undercut
12. Use of metal inserts

Inserts of various types are used with plastics. The most common are
threaded metal inserts; either internally threaded nuts or externally threaded
studs.
There are several methods of installing the inserts.
Ultrasonic
Thermal
Self-tapping
Press-fit and
Molded-in

Typical Threaded Metal Inserts

13. Threads

The molding process accommodates thread

forming directly in a part, avoiding the
expense of secondary, thread-cutting steps.
The cost and complexity of the tooling
usually determines the feasibility of molding
threads
Most of the mechanisms for molding
internal threads — such as collapsible and
unscrewing cores — significantly increase
the mold’s cost and complexity

Thread Profiles
14. Surface & Finish

A high glossy finish may be achieved with proper molding conditions

and polished molding cavities.
High-gloss polished cavities require careful handling and protection
during processing
Great care should be exercised when removing high gloss parts from
the mold to avoid scratches.
Textured part surfaces have a special visual and hepatic appearance,
e.g. soft touch. Compared to surface treatments, texturing is relatively
cheap.
Mold texturing include -
Photo chemical etching
EDM
Engraving
15. Shrinkage
Shrinkage is inherent in the injection
molding process. Shrinkage occurs
because the density of polymers varies
from the processing temperature to the
ambient temperature
Shrinkage or the mold shrinkage is the
difference between the mold cavity
dimensions and the corresponding
component dimensions
Semi-crystalline materials are prone to
more shrinkage when compared to the Processing and design parameters
amorphous materials. When that affect shrinkage
crystalline material are cooled below
their transition temperature, the
molecules arrange themselves in more
orderly way. On the other hand the
micro structure of amorphous
materials does not change with the
phase change.
In evaluating prototypes, consider the following questions:

MOLDABILITY
• Does it mold well?
• Do hot or cold spots develop during molding?
• Does it release from the tool reliably?
• How much shrinkage occurs, especially in critical part areas?
• Is the part within tolerances?
• Is cycle time adequate?
• How broad is the processing window?
• Does regrind produce satisfactory parts?
PART CHARACTERISTICS
• Does the part have the proper tolerances?
• Did it warp, bow, or have other distortions?
• What are areas of potential failure, e.g.; weld lines?
• Does the part have sink, flow marks, or other surface defects?
ASSEMBLY
• Can the part be properly mated to other ones?
• Are there any fit interferences?
• Does it work in the overall system?
• Does it meet assembly, mechanical, thermal, electrical environmental, and
other test protocols, e.g. screw attachments, maximum load at minimum and
maximum temperatures, creep, and chemical exposure?
• Can the assembly be made more efficient?
Recent developments in Plastics
MetaFuse™ Nanometal/Polymer Hybrid Solution

New Nanometal/Polymer Technology Offers:

• Increased strength and stiffness at minimum weight.
• Higher temperature performance.
• Hard, wear resistant coating.
• Permeation resistance, conductivity and dimensional stability.

Nanocrystalline Metals Comparison to high strength metals

MetaFuse™ NanoMetal/Polymer Hybrid Solution

Nanocrystalline metal clad on polymer offers high performance with new

design freedom:

• Designing for high strength and stiffness at minimum weight

• Direct fabrication of structural components in complex shapes
• Improving strength, stiffness and creep of plastic parts at elevated
temperatures
• Adding hard, wear resistant coating to plastics
• Make plastics more impermeable, conductive and dimensionally stable
• Aesthetics / metal look
Plastics in Automotive applications

Manifolds

Water jacket spacer for

Engine block

Engine Covers
Thank you