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How To Choose The Wall Thickness

BY PLASTIC MOLD / ON MAY 24, 2015 / IN PLASTIC MOLD

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Local thick wall thickness, wrong
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position of gates and cooling layout
would lead to sink marks, trapped air,
Posts deformation and burns on the injection

Automotive
parts, the following will analyze some
Injection Molding: factors:
Enhancing
Durability and
Aesthetics Wall Thickness:
How to
Communic
ate The wall thickness should keep same to
Effectively
avoid the sharp transition zone and big
with Your Privacy - Terms
 China Mold
different cross-section.Otherwise, they
Maker in
2023 will invite the uneven shrinkage, which is
A Step-by-Step
a reason for the drawback of the
Guide to Crafting
Your Own Fishing surface.The wall thickness scope is
Lure Molds
between from 1 to 6mm; normal
～ ，
Medical Plastic
Injection Molding: average thickness is 1.8 3mm which
A Complete Guide
to Manufacturing
depends on the geometry of plastic part
Medical Devices and plastic material.
Avoid These 10
Common Mistakes
When Choosing a
China Injection
Molding Supplier

Also the wall thickness design is related

with the flow distance of the melt
plastic; the flow distance is a cover
space of melt plastic from gate to the
far end of the cavity. Under normal
process, the flow distance is
proportional to the thickness of plastic
parts. The larger the plastic wall
thickness is, the longer the flow distance
will be.

The flow distance lists as follows for

wall thickness 2.5mm

ABS ： 220 mm； PC ： 120 mm；

 ：
HDPE 280 mm ； POM ： 180 mm;
the problems invited by uneven wall
thickness:

1.Local thick wall would lead to the sink

marks on the surface:

The thin wall would lead to hesitation

flow
Spigot: gradual transition wall thickness
design would eliminate the white spot
on the surface

On the picture below, the slot is too

deep, which lead to the deformation of
the bottom and the solution is to deduce
the depth of the slot and make the wall
thickness even.

Glossing: the sharp corner will lead

to glossing
Component wall thickness requires
several competing factors to be taken
into consideration. The mechanical
requirements of a section may dictate a
certain wall thickness. However, thick
sections should be avoided because of
the requirement to remove heat
efficiently (the cooling part of the cycle
is the time that limits the production
rate), the need to avoid sinking ，
cavitation and warping. Thin sections
should be avoided because of the need
for the melt to flow easily to fill the
cavity. Economic factors often dictate
the final wall thickness selected
(amount of material used, etc.). If a wall
is too thin for the strength properties
required, the wall can he reinforced with
ribs (see below). Flow characteristics
vary from one plastics material to
another and Tabic 1.2 gives typical
values for wall thicknesses.

Wall Thickness
Recommendations (Mm)

Material
ABS l.00-3.50

Acetal 0.50-3.15

Acrylic 0.65-3.80

Cellulosics 0.65-10.00

Liquid crystal
0.20-3.00
polymers

Long fibre plastics 1.90—

(Vcrtons) 25.00

Nylons 0.25-2.95

Polyarylate 1.15-3.80

Polycarbonates 1.00—3.80

Polybutylene
丨
terephtha ate
0.65-3.20

Polyethylene (LD) 0.50-6.35

Polyethylene (HD) 0.75-5.00

Polyphenylene 0.50-4.55
 sulphide

Polypropylene 0.65-3.80

Polysulphoncs l.(X)-3.80

Modified PPO 0.75-3.55

Polystyrene 0.85-3.80

SAN 0.85-3.80

UP VC 1.00-3.80

Range Of Flow Path Ratios

For Some Common Plastics

ABS 80-150

Acetals 100-250

Acrylic 100-150

Nylon 6 140-340
Nylon 6,6 180-350

Polybutylenc
160-200
tcrephthalatc

Polycarbonate 30-70

Polyethylene (HD) 150-200

Polypropylene 150-350

about
Polystyrene
150

about
HIPS
130

Polysulphoncs 30-150

Polyvinylchloride about
(unplasticiscd) 60

Polyvinylchloride up to
(plasticised) 180

about
SAN
140
Table 1.3 Courtesy of J.A. Brydson
(1990) Handbook for Plastics
Processors% Hcincmann Newncs.

Wall thickness should be constant if

possible. If not, the transition between
thick and thin sections should be
gradual because abrupt changes lead to
internal stresses due to flow problems
and different cooling rates. In general ，
the ratio of thick to thin should not be
greater than 3:1. A further point is that in
filling such a section, the flow must be
from thick to thin.

，
For any section thickness there will be
a limit to the length of flow (flow path)
possible. This is because as the plastic
，
melt flows along a section it cools
producing an increase in melt viscosity
and ultimately it sets up (hardens)
thereby preventing the section from
being completely filled. The ability to
flow along a path depends on the path
thickness, the type of plastics material
and the particular grade (easy flow or
stiff flow) of that material. It will also
depend on moulding conditions. A guide
to flow characteristics of materials in
this respect is given by the flow path
ratio which is the ratio of the length of
flow possible per unit wall thickness.
Table 1.3 gives the range of flow path
ratios for some common plastics
materials.

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