Final Report Sharky Visit - Team 1

Sharky Factory
Design and Production – Senior 1
Plastic Mold Design &

Injection & Blowing
Submitted to:
Dr. Tayseer Attia
Dr. Ahmed Awad
Ain Shams University

Faculty of Engineering
Spring 2023
Plastic Mold Design & Injection &
Blowing MDP486s: Selected Topics in
Manufacturing
Student Name ID
(1)- Mena Gerges Labeb 1900064
(2)- Kareem Hossam Eldein Mohamed 1900208
(3)- Mostafa Mohamed Abo Mosalam 1900543
(4)- Mohamed Maher Elewa 1901730
(5)- Omar Mohamed Farid Hassan 1900956
(6)- Yousef Ahmed Farghly 1900161
(7)- Marim Ibrahim Abdelsalm 1901441
(8)- Amal Mohamed Ali 1900261
(9)- Taha Radwan Taha 1804912
(10)- Abanoub Youssef Soliman 1901049
(11)- Mohamed Wahed Ahmed 1901648
(12)- Eman Rabea Moustafa 1901637
(13)- Mahmoud Abdelaziz Gabr 1901596
(14)- Mostafa Mohamed Alaa El Den 1901093
(15)- Hossam Mohammed Saber 1902343
(16)- Abdallah Mohammed Abdallah 1901938
(17)- Mohamed mahmoud gouda Abdallah 1901522
(18)- Ahmed Mohamed Lasheen 1901192
(19)- Omar Mohamed Eissa 1801847
(20)- Yara Mohamed Salah 1900479
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Manufacturing
Table of Contents
Introduction ....................................................................................................... 5
Mold Design
Plastic Mold Design & Parts .............................................................................. 9
Injection Mold Sliders ...................................................................................... 13
Cooling Systems ............................................................................................. 18
Gating Systems ............................................................................................... 20
Ejectors ........................................................................................................... 24
Injection department
Injection Process ............................................................................................. 28
Blowing Department
Blowing Process .............................................................................................. 38
Overview...................................................................................................... 38
The pros and cons of blowing section from our point of view ....................... 38
What We Got from This Visit? ...................................................................... 39
Blowing Machine.......................................................................................... 39
Plastic Extrusion Blow Molding Machine: ..................................................... 40
Automatic Single/Double Station Blow Molding Machine: ............................ 41
Machine Parameters.................................................................................... 42
Advantages of Machine ............................................................................... 44
Defects of Blowing ....................................................................................... 45
Parison ........................................................................................................ 46
Varity of products ......................................................................................... 46
Material specifications ................................................................................. 47
Referances ................................................................................................ 46
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Manufacturing
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Manufacturing
Introduction
About Factory
 The early beginning of the company was in 1983 as a sole proprietorship.
 It has high quality injection molding plastic products that serves different
industries as textile, cosmetics, detergents, home appliance, medical
devices, and more.
 It has high quality extrusion blow molding plastic containers that serves
different industries as detergents, chemicals, cosmeceuticals, home
appliance, and more.
 Injection molds, blowing molds, and spare parts
Purpose of Visit
 The purpose of the factory visit is for us to understand the size of the plastic
industry in Egypt and to get more and more familiar with the industry.
 We also want to learn more about the various injection molding and blow
molding processes and to learn more about the design of molds.
 to get a closer real-life hands-on experience about production facilities
and challenges
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Manufacturing
Disadvantages That Showing in Factory & Suggestion to Solve

It
 If a machine is faulty in such a place, we must expedite maintenance
operations to increase production.
 The workspace is small, and we are trying to expand the place.
 If possible, separate the blowing machine, injection machine, and
manufacturing workshop.
 Provide fire extinguishers for the place.
 Workers of a young age must have a specific age limit for employment.
 We put lines and arrows drawn on the ground to indicate the end of
production when it comes out of the machine so that it does not exceed the
limit and block the exit path as a safety measure.
 We put arrows indicating how to quickly exit the factory from any location
in the factory as an escape plan.
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Manufacturing
 For example, most workers wear

hand-free devices, so if any strange
noise occurs in the machine or factory,
they can be alerted after a while.
Workers must comply with health and
safety precautions.
 Adding warning signs in workshops is
essential to clarify potential hazards
personal protective equipment
and warn against dangerous
areas. Warning signs such as bright
colors and prominent images can be used to indicate potential dangers.
Written warning signs in the local language or English can also be used to
enhance understanding.
Warning sign
Advantages of Factory That Show

 The number of defects in the products that are released to the outside is
low, and they were being recycled.
 The spirit of work and collaboration is high.
While the workers were working and we were visiting, they were divided
into groups - one group for design, one group for blowing, and one group
for injection.
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Manufacturing
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Manufacturing
Plastic Mold Design & Parts

Main Concentration Overview
"In this field, during our visit to the factory, the design engineer explains all the
components of plastic injection mold design and blowing mold design with some
examples and details.
Plastic Injection Molding

 Plastic injection mold design is the process of creating a custom mold for
the production of plastic parts using the injection molding process.
 The design of the mold is a crucial factor in the success of the injection
molding process, as it determines the shape, size, and quality of the
finished product.
Design of Mold Steps

 The designer must create a 3D model of the
part that will be produced, using software such
as CAD (computer-aided design). (We used
Solid Works)
 This model is then used to create a mold
design that includes the cavity and core
shapes, the gating system, and the cooling
Example Design from Solid work
system.
 The designer must consider factors such as
1. The type of plastic material to be used.
2. Shrinkage allowances of the material
3. The size and complexity of the part.
4. The required production rates.
Benefits of using Plastic Injection Molding

 High efficiency with fast production
 Better materials compatibility - Enhanced strength
 High tolerances and greater precision
 Product flexibility
 Using multiple plastics
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Manufacturing
Main Components of Injection Mold
Mold Base
 The mold core and mold cavity are each mounted to the mold base, which
is then fixed to the platens inside the injection molding machine.
 The front half of the mold base includes a support plate, to which the mold
cavity is attached, the sprue bushing, into which the material will flow from
the nozzle, and a locating ring, in order to align the mold base with the
nozzle.
 The rear half of the mold base includes the ejection system, to which the
mold core is attached, and a support plate.
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Manufacturing
Example of Mold Base

Parts of Mold Bases
Mold channels
 First, the molten plastic enters the mold through the sprue.
 Additional channels, called runners, carry the molten plastic from the sprue
to all of the cavities that must be filled.
 At the end of each runner, the molten plastic enters the cavity through a
gate which directs the flow.
 However, sometimes hot runner systems are used which independently
heat the channels, allowing the contained material to be melted and
detached from the part.
 Another type of channel that is built into the mold is cooling channels.
These channels allow water to flow through the mold walls, adjacent to the
cavity, and cool the molten plastic.
Function of its part

 The cavity and core shapes: determine the shape of the plastic part, and
they must be designed to ensure that the finished product meets the
required specifications.
 The gating system controls: the flow of the molten plastic material into
the mold, and it must be designed to ensure that the plastic flows smoothly
and evenly into the cavity.
 The cooling system: is used to rapidly cool the plastic part after it has
been molded, & it must be designed to ensure that the part retains its shape
& does not warp or deform.
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Manufacturing
After Design process

 Once the mold design is complete, the mold can be manufactured using a
variety of techniques, including CNC machining, EDM (electrical discharge
machining), and wire cutting.
 The final mold must be precise and durable, as it will be subjected to high
pressures and temperatures during the injection molding process.
Milling CNC Machine Milling CNC Machine
Images from Sites
Fixed Plate Movable Plate
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Manufacturing
Injection Mold Sliders

Main Concentrations Overview
On our visit to the factory, the design engineer explains the different types of
sliders and their purpose in plastic injection molding and how to choose or design
the right slider mechanism for a specific product.
What is an injection mold slider？

 injection mold slider is a tool used in
the injection molding process. It
helps create uniformity and
consistency in the final product.
 Without it, the process would
become more difficult and time-
consuming.
 A slider is a mold component that Slider Parts
injection mold slides perpendicular to or at a certain angle to the opening

and closing direction of the injection molds during the opening and closing
action.
Usage
 The injection molding slider is used when the product structure makes it
impossible to mold release direction without the use of the slider.
Material
 The slider material itself has the appropriate hardness and wear resistance
to withstand the friction of the movement.
 The hardness of the cavity or core part of the slider should be the same
level as the rest of the cavity and core.
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Manufacturing
Types of Slider Pulling Mechanism Can Be Used in Mold Design

1. Cylindrical Pin Type Angle Slider Core-Pulling Mechanism.
 When ejecting, the core is pulled
out and the product is ejected by
the ejector pin.
 The angle slider has a chute on
both sides.
 Cylindrical pins are provided on
both sides of the mold sleeve for
guiding the angle slider. Cylindrical Pin Type angle slider core
2. Angle Pin Type Angle Slider Core-Pulling Mechanism.

 When ejecting, the stripper
plate pushes the angle slider.
 At the same time, the core
floats a certain distance. This
eliminates the tension of the
angle slider on the die bush.
Continue to ejector and the
part is removed from the core. Angle Pin Type Angle Slider Core
3. Guide Plate Type Angle Slider Core-Pulling Mechanism.

 When ejecting, the angle slider is pushed by ejector pin to complete the
core pulling.
Guide Plate Type Angle Slider Core
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Manufacturing
4. Roller Eject Type Angle Slider Core-Pulling Mechanism.

 When the mold is opened, because
the plastic part has a large tightening
force for the fixed mold core.
Therefore, the fixed mold Stripper
plate is used to release the plastic part
from the core to the movable mold
under the action of the spring.
Roller Eject Type Angle Slider Core
 When ejecting, the roller contacts the
angle slider to reduce friction.
5. Wedge Block Outer Core-Pulling Mechanism.

 When the mold is opened, due to the
action of the inclined surfaces on
both sides of the wedge block, the
slider is slid and shaped in the guide
groove to complete the core pulling.
Wedge Block Outer Core
6. Angle Slider Outer Core-Pulling Mechanism.

 The ejector plate pushes the angle pin, and drives the slider to move in
the oblique direction of the angle pin to complete the split core pulling
action. And the plastic part is ejected under the action of the ejector pin.
Angle Slider Outer Core
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Manufacturing
7. Angle Slider Core-Pulling Inside the Mold.

 The head of the slanting pin is a
forming slider, and a slanting hole is
in the male mold for reducing friction.
 The bottom of the slide bar can be
provided with a roller, and the
slanting bar moves along the
inclined hole under the action of the Angle Slider Core-Pulling Inside the Mold.
ejector device. The plastic part is
ejected while pulling the core.
8. Angle Slider Discontinuous Inner Core-Pulling Mechanism.

 After the mold is opened, under the
action of the ejector.
 Move the angle slider along the guide
slot of the core. The angle slider is
pulled out from the plastic part, and
the plastic part can be taken out.
Angle Slider Discontinuous Inner Core
9. Angle Slider Outer Parting.

 When the mold is opened, it slides in the groove of the tapered mold sleeve
under the action of the push rod. Separate to both sides while rising. The
plastic part is also gradually separated from the main core. The limit screw
acts as a slider limit.
Angle Slider Outer Parting
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Manufacturing
10. Angle Slider Stop Structure.

 When opening the mold, leave the slider in
the moving mold.
 Need to set the stop device. A spring pin is
placed between the stationary molds.
 The pressure of the spring is used to help
the angle slider stay in the movable mold. Angle Slider Stop Structure.
11. The Guiding Effect of The Main Core on The Plastic Part.
 The main core disposed on one side of the
movable mold extends into the plastic part
to maintain the center position of the
plastic part. Let it leave each slider at the
same time.
The Guiding Effect of The Main

Core
12. Push the Slider and Plastic Parts
Simultaneously with The Stripper Plate.
 To evenly force the plastic part, sometimes the push rod of the pusher is
added in addition to the push rod of the push-sliding slider, so that the two
moves synchronously.
Push the Slider and Plastic Parts

Simultaneously with The Stripper Plate
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Manufacturing
Cooling Systems
Cooling systems are an essential component in the injection molding process.
The cooling system is responsible for regulating the temperature of the mold and
ensuring that the plastic material solidifies correctly. In this report, we will discuss
the design of cooling cavities, their relationship with the die, preferable designs,
and working systems.
Design of Cooling Cavities

 The design of cooling cavities is
critical to ensure that the plastic
material cools uniformly and
solidifies correctly.
 The cooling cavities are typically
designed to follow the shape of
the mold cavity. They are placed
as close as possible to the mold
cavity to ensure maximum heat
transfer.
 The size and shape of the cooling Cooling Systems
cavities depend on several

factors such as the size and shape of the mold cavity, type of plastic
material used, and production requirements.
 The number and location of cooling cavities also play a crucial role in
determining how efficiently heat is transferred from the mold cavity to the
coolant.
Relation with Die

 The design of cooling cavities is closely related to that of the die.
 The die must be designed in such a way that it allows for efficient heat
transfer from the mold cavity to the coolant. This means that there should
be enough space between each cooling cavity to allow for proper coolant
flow.
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Manufacturing
Preferable Designs
 There are several preferable designs for cooling systems in injection
molding. One common design is a straight-through system where coolant
flows through a channel directly into each cooling cavity.
 Another design is a spiral system where coolant flows through a spiral
channel before entering each cooling cavity.
Working Systems
 Cooling systems can be either passive or active. Passive systems rely on
natural convection or radiation to dissipate heat from the mold cavity.
 Active systems use pumps or fans to circulate coolant through channels
within or around the mold.
Design of Cooling Systems
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Manufacturing
Gating Systems
Sprue
 Sprue in injection molding is the
channel through which molten
plastic flows from the injection
molding machine nozzle into the
mold cavity.
 It is an essential component of the
injection molding process, as it
controls the flow of plastic and
ensures that it fills the mold cavity Sprue
evenly.
Design Considerations
should be tapered 3~5° inclusive angle
to be pulled out of the mold more
easily
should also be highly polished in the
line of draw
 to assist withdrawal
 to induce more efficient flow
diameter at the narrow end should be
larger than the machine cylinder
nozzle opening
Runners
 Runners in injection molding are channels or
pathways that allow molten plastic to flow
from the injection molding machine nozzle to
the cavities of the mold, also they help to
distribute the plastic evenly throughout the
mold and ensure that each cavity is filled with
the correct amount of material. Sprue & Runner & Gate
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Manufacturing
 The runners are typically designed to be smaller in diameter than the part
being produced, which helps to reduce waste and minimize cycle times. Once
the plastic has cooled and solidified, the runners are removed from the
finished product and recycled.
Runner Types
 There are several different types of runners used in injection molding,
including:
1. Cold runners: These are simple channels that carry molten plastic from the
machine nozzle to each cavity of the mold. They are easy to design and
manufacture but can result in excess waste material.
2. Hot runners: These use a heating system to keep the plastic molten as it flows
through the runner system. This reduces waste and improves efficiency but can
be more complex and expensive to implement.
Runner’s design
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Manufacturing
 full round cross-section: Full round is the most efficient runner shape. It has
the lowest pressure drop over the same volume of material.
 The only disadvantage is that the runner must be cut into both A and B runner
plates which requires that the two halves match up when the mold is closed
(alignment should be within 0.001inch).
 trapezoidal one: for three-plate molds
 semi-circular or half round one: severely restricts flow although
 frequently used
 square and rectangular ones: should never be used
Gate
 Gate in injection molding refers to the opening through which molten plastic is
injected into the mold cavity.
Type of Gates
1. Sprue gate: This is the simplest and most common type of gate, where the
molten plastic is injected through a single opening at the top of the mold.
2. Edge gate: This type of gate is used for thin-walled parts and allows for
easy removal of the part from the mold.
3. Submarine gate: This type of gate is used for parts that require a high
degree of precision and accuracy.
4. Hot runner gate: This type of gate uses a heated manifold to keep the
plastic molten as it flows into the mold cavity, resulting in faster cycle times
and reduced waste.
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Manufacturing
Gate Location
 should be selected in such a way that rapid and uniform mold filling is ensured
and weld/meld lines and air vents are positioned properly
 should be positioned away from load-bearing areas because the high melt
pressure and high velocity of flowing material causes the area near the gate
to be highly stressed
De-gating
In injection molding refers to the process of removing the excess material or
gate from the molded part after it has been formed. Hooks gate de-gating is a
specific type of de-gating method that uses hooks to remove the gate from the
molded part.
hook gates
Hooks gate de-gating design involves
installing hooks on the die where the
gate is located.
These hooks are used to grab and pull
the excess material away from the
molded part.
The design of these hooks can vary
depending on the shape and size of the
gate.
Hook's Gate
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Manufacturing
Ejectors
 Injection molding ejectors are an integral part of the injection molding
process, which is a widely used manufacturing method for producing plastic
parts and components.
 Ejectors play a crucial role in the ejection of molded parts from the mold
cavity after the plastic has been injected, cooled, and solidified.
 This detailed report will provide an overview of injection molding ejectors,
their types, functions, design considerations, and common issues
associated with them.
 Provide a brief overview of the factory's injection molding operations,
including the types of products manufactured and the overall production
capacity.
 State the purpose of the report and its significance in enhancing the
factory's understanding and optimization of ejector pin usage.
Types of Injection Molding Ejectors:

Ejector Pins:
 These are cylindrical pins that are
positioned in the ejector plate and
extend into the mold cavity. When the
ejector plate moves, the pins push Ejectors Pin
against the part, ejecting it from the
mold.
Blade Ejectors:
 These are thin, flat blades or plates that
are used to eject larger parts. They
provide a larger surface area for pushing
against the part, enabling effective
Blade Ejectors
ejection.
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Manufacturing
Stripper Ejectors:
 These consist of a plate or pins that move
laterally to strip the part off from undercuts or
complex features.
Stripper Ejectors
Functions of Injection Molding Ejectors:

Part Ejection:
 The primary function of ejectors is to remove the molded part from the mold
cavity after it has solidified.
Mold Release:
 Ejectors assist in breaking the adhesion between the part and the mold
walls, facilitating easy release.
Cycle Time Optimization:

 Efficient ejector design and operation contribute to reducing cycle times by
swiftly ejecting parts and preparing the mold for the next cycle.
Function of Ejectors
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Manufacturing
Design Considerations for Injection Molding Ejectors:

Ejector Placement:
 Ejectors should be strategically positioned to ensure effective ejection
without damaging the part or interfering with the mold's intricate features.
Ejector Pin Size and Quantity:

 The size, length, and number of ejector pins depend on factors such as
part size, complexity, and ejection force required.
Ejector Stroke:
 The stroke length of ejectors should be carefully determined to ensure
complete part ejection while avoiding excessive forces that could damage
the mold or part.
Ejector Plate Design:

 The ejector plate must be robust and properly supported to withstand the
ejection forces and prevent deflection.
Common Issues with Injection Molding Ejectors:

Ejector Pin Marks:
 Improper ejection can leave visible marks or indentations on the part's
surface. Proper ejector design and polishing techniques can mitigate this
issue.
Sticking or Binding:
 Inadequate lubrication or improper maintenance can cause ejectors to stick
or bind, resulting in incomplete ejection or damage to the mold.
Part Deformation:
 Inefficient ejection can lead to part distortion or warping. Optimizing ejector
design and stroke can help prevent such issues.
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Manufacturing
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Manufacturing
Injection Process
Overview Introduction:
 In this report we analyze and provide an overview of the injection process
defects identified in [Sharky Factory].
 The injection process is a critical step in manufacturing, and any defects can
result in quality issues, production delays, and increased costs.
 This report aims to identify the root causes of the defects, assess their impact,
and propose appropriate corrective actions.
Injection Machine
 The factory has 6 injections machine to
produce 5 types of hangers
 Two machines required to produce 1 type
of hanger so one of them has low
productivity than the second so we
reduce the force and to make the second
has the same productivity of the first
machine to make better utilization. Injection Machine
Clamping Unit
Specs of Factory Machine
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Manufacturing
Injection Unit
Attachment of machine
1. Unique double linear guide tracks: Improve
injection accuracy and stability
2. High efficiency screw and barrel: storage and
mixing the product and the screw act as a ram
Feed Hopper
to inject the molten polymer
3. User friendly safety devices: enclosed barrel and hopper and shelter and
manual pressure releasing and lubricant sys
4. Nozzle: rigid and stable and it’s the injecting point
5. Heaters: heat the polymer and melt it has five heaters gradually rise in temp
from 175C to 220C the highest temp at the injection point
6. Water line: to cool the machine and cooling the product:
7. Indicator of oil in the machine
8. Indicator of the material in the machine
Cylindrical Barrel with Heater Water Line Oil Indicator
Schematic for Machine
29
Manufacturing
Time of the cycle

 It is 17 second to produce 1 type of hanger and it has 4 products so the time
to produce 1 product is 4.25 second
Control
 F1: to control the heaters
 F2: to save the mold data and choose which data
will we choose
 F3: to control the clamping sys so we can control
its speed and pressure and the distance
 F4: to control the eject sys so we can control the
distance that it sill eject for and if the ejector will
eject at one step or two steps (if it needed)
 F5: to control the core if the product has thread or
we will work manually if needed
 F6: to control the nozzle: if we need to get the
machine back manually for any reason
 F7: to control the injection sys and control its
speed and distance and pressure
 F8: to over view of the machine
30
Manufacturing
Sensors on Clamping unit

Sensor for checking the temperature inside the mold which takes by
monitoring screen to check the suitable temperature for the process, if there is
a problem check the electric line of the monitor or change the sensor with new
one.
Sensor for checking if the ejector returns to its original position if it not
returns to its original position the process will stop to prevent the damage will
occurs in the ejector or the mold.
Sensor to checking if the safety sliding door is closed to make sure the
operator is safe during the operation.
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Manufacturing
Material
 99% of the material used in injection machine is
Polypropylene (PP)
Mass
Its example of problems in the machine happens when
product didn’t get out of the machine for any reason so Polypropylene Material
from sabic
that lead to the material will freeze on the nozzle that lead
to the injection process will not happened
Solution
We heat the nozzle with bushberry) ‫ )بشبوري‬the we
give the machine order to inject manually to make
sure that the nozzle get red of any frozen polymer
Clamping unit specs in our machine
32
Manufacturing
Defect Types:
The following defects have been observed during the injection process:
Short Shots:
 Short shots occur when the injected material does not completely fill the mold
cavity, resulting in incomplete parts. This defect is typically caused by
inadequate injection pressure, insufficient melt temperature, or improper
cooling.
Example of Short shots from factory Example of Short shots from factory
Flash:
 Flash refers to the excess material that
escapes between mold parting lines,
resulting in thin protrusions on the finished
part.
 This defect is commonly caused by
excessive injection pressure, or excessive
temperature worn-out molds, or misaligned
mold components. Flash Defects
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Manufacturing
Burn marks:
 Burn marks are dark or blackened areas on
the surface of molded parts. These marks
can be localized or spread across the entire
part and are often accompanied by an
unpleasant odor.
 Burn marks not only affect the visual
appearance of the product but may also
compromise its structural integrity. Burn Marks
 This defect is typically caused by High

Injection Temperature or Excessive injection pressure can generate excessive
heat and Improper mold temperature control.
Warpage:
 Warpage refers to the distortion or bending of the
molded part from its intended shape.
 It can occur due to non-uniform cooling, improper
mold temperature, or inadequate mold clamping
force.
Warpage
Matured discoloration:
 Matured discoloration is characterized by
permanent or long-lasting color changes in the
molded parts, which occur after the initial production
process.
 The discoloration may manifest as fading,
darkening, or changes in hue, resulting in an
inconsistent appearance compared to the desired
color specifications. Example of Matured
discoloration
 This defect is typically caused by Some materials
used in the injection process may be prone to degradation when exposed to
heat, light, or environmental factors. or Inconsistent Material Mixing or Mold
Contamination.
34
Manufacturing
Some examples of Matured discoloration
Root Causes:
After a thorough analysis, the following root causes have been identified for the
injection process defects:
Inadequate Process Control:
 Insufficient monitoring and control of injection parameters, such as
temperature, pressure, and cooling rates, can contribute to various defects.
Mold Design and Maintenance:
 Defects can arise from suboptimal mold designs or the presence of worn-out
or damaged mold components.
Material Quality:
 Poor material quality, such as inconsistent melt flow or impurities, can lead
to defects during the injection process.
Operator Error:
 Improper setup, incorrect adjustment of process parameters, or insufficient
training of operators can result in defects.
35
Manufacturing
Corrective Actions:
 Process Optimization:
Conduct a comprehensive review of injection parameters and optimize them
to ensure consistent and reliable production.
 Mold Inspection and Maintenance:
Regularly inspect molds for wear, damage, or misalignment and perform
necessary maintenance or repairs.
 Material Testing and Control:
Implement strict quality control measures for incoming materials, including
testing melt flow, purity, and other relevant properties.
 Operator Training:
Provide comprehensive training programs to operators to ensure proper
setup, adjustment, and monitoring of the injection process.
 Continuous Improvement:
Establish a culture of continuous improvement, encouraging employees to
identify and report defects, and implementing corrective actions promptly.
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Manufacturing
37
Manufacturing
Blowing Process
Overview
Products of factory in this department Layout of Factory
The pros and cons of blowing section from our point of view
Pros:
 The efficiency of the workers, the quality of manufacturing, the diversity in the
field of products in shape and size, the speed and accuracy of production, and
finally the commitment of the workers and engineers to their roles within the
work environment.
Cons:
 I believe the most negative aspect is the working environment surrounding the
worker. There is very high noise and narrow spaces between the machines,
and the worker's sitting area lacks ventilation from all sides.
 Also, safety is not fully achieved as the temperature of the product that the
worker holds in their hand is directly high, and children under the legal age are
employed.
 Finally, it is noticeable that the worker moves a lot back and forth to the
recycling area.
38
Manufacturing
What We Got from This Visit?

 This visit helped better understanding ability to produce a variety of plastic
products in different shapes and sizes, ability to produce lightweight products
with high strength, durability and reduce waste in the manufacturing process
by recycle and reuse raw materials, making it more environmentally friendly.
We encountered the industry pulse!
Blowing Machine
 ToNgDa Ht-2L Extrusion Blowing Molding Plastic Bottle Making Machine:
Blowing Machine
39
Manufacturing
Basic info:
Extrusion Blow
Model NO. HT-2L Type Molding
Machine
Rotary Cylinder
Festo Station Double
Brand
Automatic Extrusion
Suitable Bottle 0.5-2L Key Words Blow Molding
Machine
Packing Wooden Use Hollow Molding
Parison Control Moog Max. Size of Mold 590*500
Hydraulic Valve Yuken Color Blue
Making Method of Extrusion-Blow

Raw Material HDPE
Parison Molding
Automation Automatic Computerized Computerized
Certification CE, ISO9001:2008 Trademark TONGDA
Transport Packaged in
Specification 3*1.55*2.35
Package Wooden Case
Origin China HS Code 8477300000
Plastic Extrusion Blow Molding Machine:

 Blow molding is a special type of plastic processing used to create hollow
plastic parts. In plastic extrusion molding machine, a plastic material feedstock
is fed through a hopper onto a feeding transfer screw.
 This feeds the material into a specially designed blow mold that directs the
flow of the material to create the extruded hollow tube.
40
Manufacturing
 Extrusion blow molding is a common blow molding technique used to process

many different plastics including HDPE, PVC, PC, PP and PETG - and is
capable of producing bottles requiring multi-layer technology.
Automatic Single/Double Station Blow Molding Machine:

1. Linear guider strip style
2. with single station or double station
3. Adopt 1-4 die mold heads
4. Multi-layers:1-3 Co-Extrusion Layers
5. Multi cavities: 1-4 cavities
6. Production Volume: 10ml-2l
7. Application Products: (lotion bottles-water bottles –shampoo bottles)
8. Optional Parison controller/Auto DE flasher/Auto material feeding /Auto
Recycling/IML (In Mold Labeling)/Leakage detector/Filling/Packing on lined
full automatic production.
9. Energy Saving:
Energy savings at least 40% greater than conventional fixed displacement pump
systems (The energy-saving effect varies depending on the operation
conditions.)
10. High Accuracy with Simple Operation
High-Accuracy servo control according to analog pressure (P) / flow rate (Q)
voltage commands
11. Longer life for hydraulic units & O sealing
MOOG Servo motor due to its instant reaction speed, it does not require always
running like traditional induction motor, so the hydraulic oil temperature is lower,
which protect the hydraulic units and O-rings to use longer life.
41
Manufacturing
12. Faster Shipping Adjustment

Simple adjustment to start a trial run on the machine, meaning a shorter
adjustment time
13. Improving the Working Environment Reduced noise during operation
14. Exceeds Standard of High Efficiency Motor regulation:
Incorporating a motor dedicated to servo-based rotational speed control
Since no induction motor is used, the maximum discharge rate of the pump does
not fluctuate depending on the power supply frequency, making it unnecessary
to adjust the machines' maximum speed for each shipping destination.
Machine Parameters
Model Units HT-2L
Specification
Station Single/Double Single
Max. product volume L 2
Dry cycle pc/h 900
Central distance of double head mm 130
Output of HDPE kg/h 50
Weight of machine kg 3300
Size of machine(L*W*H) m 3*1.55*2.35
Die head
Max. die diameter (single head) mm 108
Die head heating zone (single head) - 3
Die head heating (single head) kw 5.2
Max. die diameter (double head) Mm 72
Die head heating zone (double head) - 5
Die head heating power (double head) Kw 7
42
Manufacturing
Clamping Unit
Platen distance Mm 138~368
Mold moving stroke Mm 320
Clamping force Kn 44
Extruder Unit
Screw diameter Mm 50
Screw length/diameter ratio - 25
Screw heating power Kw 6.8
No.of heating zone(screw) - 3
Power Unit
Oil pump motor power Kw 7.5
Screw motor power Kw 11
Total power Kw 30.5
Remarks
Air consumption m³/min 0.4
Blow pressure Map 0.6
Cooling water pressure Map 0.3
Water consumption L/min 30
Max size of mold(W*H) mm 310*320
43
Manufacturing
Some Photo from Site
Blow Pin Extruder
Feed Hopper Cylindrical Barrel of Extruder
Advantages of Machine
1. Need long time to change the mold
2. Need one to check every hour to find is all things is right
3. Need a lot of maintenance
44
Manufacturing
Defects of Blowing
Defect cause Photo
Barrel
Reduce coo4ling time
shape
Wrinkle Very low cooling temp
Very small The presence of dust in

holes the row material or mold
Incomplete There is not enough raw

product material to fill the mold
The pen is moved from

his position so the
Not proper
product sticked in the
product
die and another product
sticked on it
45
Manufacturing
Parison
-The same product can be made with the same amount of raw material, but
with different thicknesses in some parts of the product, and this is due to
 Parts that require higher strength than the other.
 To avoid fracture of products during overloading.
-It is in the machine and is easily controlled
Varity of products
 we can produce many types and shapes by blowing by using same machine
but different mold
 Colored products using dyes
 line indicates the height of the liquid inside the product by placing another
hopper in a different color at the pro pin
Some Products produce from Blowing
46
Manufacturing
Material specifications
 From Sidi Kerir Petrochemical Company
Unit of Test
Property HD5301EA HD5502GA HD5403EA
Measurement Method
Melt flow
rate 𝑔/10𝑚𝑖𝑛 ISO1133 0.05/11 0.2/30 0.35/30
(2.16Kg)
Density 𝑘𝑔/𝑚 ISO1872/1 953 955 955
Tensile
strength at 𝑀𝑝𝑎 BP13B/1 25 25 26
yield
Elongation
% BP13B/1 1030 1000 950
at break
Flexural ISO178-
𝑀𝑝𝑎 1050 1000 1070
modulus 1975
Impact
resistance, 𝑚 BP13B/1 4.4 3.3 2.4
F50
RSCR, 50⁰C ℎ𝑜𝑢𝑟𝑠 BP 360 25 15
47
Manufacturing
References
1- Lecture Notes
2- Sharky Factory
3- Rosato, D.V., and Rosato, M. Injection Molding Handbook. Springer
Science+Business Media, LLC, 2012.
4- Rosato, D.V., and Rosato, M. Plastics Processing Data Handbook.
Springer Science+Business Media, LLC, 2016.
5- Pappas, M.G. Injection Molding: An Introduction. Hanser, 2014.
48

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Sharky Factory

Design and Production – Senior 1

Plastic Mold Design &

Ain Shams University

(2)- Kareem Hossam Eldein Mohamed 1900208

(3)- Mostafa Mohamed Abo Mosalam 1900543

(4)- Mohamed Maher Elewa 1901730

(5)- Omar Mohamed Farid Hassan 1900956

(6)- Yousef Ahmed Farghly 1900161

(7)- Marim Ibrahim Abdelsalm 1901441

(8)- Amal Mohamed Ali 1900261

(9)- Taha Radwan Taha 1804912

(10)- Abanoub Youssef Soliman 1901049

(11)- Mohamed Wahed Ahmed 1901648

(12)- Eman Rabea Moustafa 1901637

(13)- Mahmoud Abdelaziz Gabr 1901596

(14)- Mostafa Mohamed Alaa El Den 1901093

(15)- Hossam Mohammed Saber 1902343

(16)- Abdallah Mohammed Abdallah 1901938

(17)- Mohamed mahmoud gouda Abdallah 1901522

(18)- Ahmed Mohamed Lasheen 1901192

(19)- Omar Mohamed Eissa 1801847

(20)- Yara Mohamed Salah 1900479

Disadvantages That Showing in Factory & Suggestion to Solve

 For example, most workers wear

Advantages of Factory That Show

Plastic Mold Design & Parts

Plastic Injection Molding

Design of Mold Steps

Benefits of using Plastic Injection Molding

Main Components of Injection Mold

Example of Mold Base

Function of its part

After Design process

Milling CNC Machine Milling CNC Machine

Images from Sites

Fixed Plate Movable Plate

Injection Mold Sliders

What is an injection mold slider？

injection mold slides perpendicular to or at a certain angle to the opening

Types of Slider Pulling Mechanism Can Be Used in Mold Design

2. Angle Pin Type Angle Slider Core-Pulling Mechanism.

3. Guide Plate Type Angle Slider Core-Pulling Mechanism.

Guide Plate Type Angle Slider Core

4. Roller Eject Type Angle Slider Core-Pulling Mechanism.

5. Wedge Block Outer Core-Pulling Mechanism.

Wedge Block Outer Core

6. Angle Slider Outer Core-Pulling Mechanism.

Angle Slider Outer Core

7. Angle Slider Core-Pulling Inside the Mold.

8. Angle Slider Discontinuous Inner Core-Pulling Mechanism.

9. Angle Slider Outer Parting.

Angle Slider Outer Parting

10. Angle Slider Stop Structure.

The Guiding Effect of The Main

Push the Slider and Plastic Parts

Design of Cooling Cavities

cavities depend on several

Relation with Die