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Plastic Design Guide: Designing Parts For Up & Down Molding Helps Control Cost
Plastic Design Guide: Designing Parts For Up & Down Molding Helps Control Cost
API engineers and designers can work with you to develop and design your plastic injection molded component. To
ensure a quality part, there are three major areas of focus throughout the design stage:
The designers and engineers at API have over 250 combined years of experience in designing parts for plastic injection
molding, selecting materials, and processing resins (specializing in engineering and high performance resins). This guide
was designed to demonstrate the basic elements of proper plastic part design.
Designing a part that can be molded with a "straight pull" or "up & down" motion is a great way to keep the cost of the
mold down. A straight pull mold is designed so that when the two halves (A side and B side) of the mold separate from
each other, there is no plastic blocking the path of the metal in the direction of the pull. Undercuts on the part cause this
blockage of path and require an action in the mold (cams, core pulls, etc.). Action in the mold can have a major impact
on the cost (and overall size) of a mold.
Proper wall thickness is one of the most fundamental requirements in designing a part for plastic injection molding.
Plastic shrinks as it cools which can lead to defects such as sink marks, voids, stresses, and warping. Plastic resin
solidifies in the mold nearer to the outside of the part (closest to the mold surface). Thick sections of a part tend to pull
inward, creating stresses, sink marks, or voids. Since thinner sections cool quicker, stress can build in the part between
thinner and thicker sections, resulting in part war page.
Draft is required on all parts in the direction of mold movement in order to allow
parts to release or eject from the mold properly. Draft is the angle in which the
part is tapered to allow it to release. As the part cools, it tends to want to shrink to
the core side of the mold. Adding draft helps the part to release. Most parts or
applications require a minimum of 1/2 to 1 degree, however 11/2 to 2 degrees is
widely accepted as the norm.
HOLES ENHANCE PART FUNCTIONALITY AND REDUCE WEIGHT
Holes can be added to a part for functionality or to reduce overall part weight (coring). Core pins are typically used to
form a hole, preventing the molten plastic from filling in that space. Through holes go all the way through a part? Blind
holes do not completely go through a part. Core pins for a blind hole are only supported by one end, so there is a greater
degree of difficulty in forming them without defect. Forming holes can lead to defects or have a negative impact on
aesthetics. Since the molten plastic flows around the core pin, it can leave a weld line (which may be visible and/or be
weaker than the remainder of the part).
1. The depth of a blind hole should be about two times the diameter of the core pin for small pins (less than 3/16")
and four times the diameter of the core pin for pins greater than 3/16".
2. Distance from the edge of a hole to a vertical surface (edge or part or rib) or another hole should be at least two
times the thickness of the part or at least the diameter of the core pin (hole).
3. Holes created in the direction of the opening/closing of the mold or parallel to the parting line are relatively easy
to produce. Holes at different angles can be created, but may require special action in the mold utilizing core
pulls or cams which can have significant cost impacts.
Ribs can be added to parts to add rigidity or stiffness. Adding ribs allows
for a part to increase strength and bear a higher load. Ribs too have
recommended guidelines to maximize functionality and minimize defects.
Radii should be added to angles to prevent sharp corners. Corners can lead to stresses, limit material flow, and often
reduce part strength.
We understand that initially, material selection may seem overwhelming since there are so many materials to choose
from. You can rest easy knowing that API has partnered with resin suppliers for over 60 years and has a multitude of
experience in manufacturing plastic parts with even the most difficult-to-process resins. Please see our basic resin
guide for a few examples of commodity and engineering resins that API has become an expert in molding.