Classification of Polymers:

•Natural and Synthetic Polymers.

•Organic and Inorganic Polymers.

•Plastics, Elastomers, Fibers and Liquid resins.

•Thermoplastic and Thermosetting Polymers.

Thermoplastic and Thermosetting Polymers:

•Thermoplastics :
• Melt on heating and solidify on cooling - any number of times.

• •Thermosets :
Initially a liquid or a semisolid or a powder, which solidify on
heating for first time(by a polymerization chemical reaction), and then
will only decompose on heating to a high temperature.
Some important plastics that we should know:
Commodity plastics:
•Olefins
Polyethylene.
Polypropylene.

•Vinyl group
Poly vinyl chloride.

•Styrene based plastics

General purpose polystyrene.
High impact polystyrene.
Acrylonitrile butadiene styrene.
Styrene acrylonitrile.

•Acrylic group
Polymethyl methacrylate.
 Engineering Plastics:
•Polyethylene terephalate.

•Polybutylene terephalate

•Poly amides

•Poly carbonate

Specialty plastics:
•Polytetra fluoroethylene

•Polyphenylene sulphide

•Polyether etherketone

•Liquid crystal polymers

 Thermosets :
•Phenol - formaldehyde

•Amino Plastics

•Epoxy resins

•Polyurethane
 Plastic Blends
What are Blends?
Blends are mechanical mixtures of chemically different polymers or
co- polymers.

What is expected of a blend?

•High performance at reasonable price.

•Modification of performance as market develops.

•Extending the performance of expensive resins.

•Generation of unique materials.

•They should be economical,competitive and should not affect other

needed properties.

•They should be easy to process.

 Most commonly used Blends:

•ABS/PVC Blends

•PC/ABS Blends

•PBT/PC Blends

•EPDM/PP
Mould Design Fundamentals
The thermal behavior of thermoplastics leads to
Melt processing techniques such as
•Injection molding.
•Extrusion.
•Thermoforming.
•Blow molding.
•Roto molding.
Reusability theoretically any number of times.

The thermal solidification of thermosets leads to

Processing methods such as
•Hot compression molding.
 !
Typical Parts in a Injection Mold Fixed
Core Back Plate

Cavity
Moving
Back Plate
Locating Ring
Push back
Pin
Sprue Bush

E Pin Slider

Ejector
Finger
Plate
Cam
Ejector
Back Plate

Spacer
Clamp Tonnage

Clamping Force Injection Forces

Flash
Created by Molten
Plastic Squeezing
Between Mold Halves

Part

Clamping Tonnage is the Rated Clamping Capacity of an

Injection Molding Machine.
Using a Machine with the Proper Tonnage Prevents Flash.
Mold Temperature

Mold Temperature is critical in

part cooling.

Uniform mold temperature

reduces the effects of
Warpage.

Commonly controlled by water

cooling channels.
 Part Ejection from the Mold
1

2 plate mold example

Knock-out pins eject the part 3

from the mold.
Mold Design Fundamentals

•Mold Types •Ejectors

•Mold Materials •Draft Angle
•Sprues •Mold Finishes
•Runners •Temperature Control
•Gates •Shrinkage
•Venting
Types of Molds
Two Plate Design
Top Clamping Exploded View
Plate
"A”
Plate
Leader Pin
"B"
Plate Support Plate

Return Pin Elector Retainer

Plate
Ejector Ejector Plate
Housing
Standard Two Plate Mold
“A” Plate

Sprue Bushing

Ejector Plate

Support Plate “B” Plate Clamping Plate

Standard Two Plate Mold

Parting Line
Standard Two Plate Mold

Two Plate
Mold
Ejection
Standard Two Plate Mold

Two Plate
Mold
Ejection

Ejected Part
Standard Two Plate Mold
Standard Two Plate Mold
 The SPRUE
•Sprue is the beginning of the melt
delivery system within the mold
•The interface between the nozzle &
the mold
 RUNNERS
Payoffs of good runner design
A runner system that has been designed correctly will:
Achieve the optimal number of cavities
Deliver melt to the cavities
Balance filling of multiple cavities
Balance filling of multi-gate cavities
Minimize scrap
Eject easily
Maximize efficiency in energy consumption
Control the filling/packing/cycle time.
 Runners Design

PL

Full Round
Most
Trapezoidal Half Round
Efficient Good Not Good
Do NOT Use!

Perimeter vs. Area is the key to a thermally efficient runner design

Unbalanced System

B A A B

B A A B
Artificially Balanced

1/8” 1/4” 3/8” 1/2”

1/2” Dia”
 Balanced System

A A A A

A A A A
Types of Gating
Manually Trimmed Auto-Ejection Trimmed
• Direct (sprue) gate  Pin gate
• Tab gate  Submarine (tunnel, chisel) gate
• Edge (standard) gate  Hot-runner (hot-probe) gate
• Overlap gate  Valve gate
• Fan gate
• Disk (diaphragm) gate
• Ring gate
• Spoke (spider) gate
• Film (flash) gate

http://3.13.111.115:5080/kms/develop/32000002.htm
Direct Sprue Gate

Sprue

Molded Part
Fan Gate

COLD
SLUG
WELL

RADIUS
Multiple Tab Gate

Knit Line
Disk or Diaphragm Gate

Runner Runner

Sprue Part
Tunnel Gate

Molded Part
Sprue

Parting
Zero Land Length
Line

Grind Flat on Gate

Side, Min. 20 Tunnel
Gate
Knock Out Pin
Fasten Pin Head To
Prevent Turning
VENTING
 Parting Line Gate

.001-.0025
Depth Vent

Note
Step
.500
.060
.050 Min.
Min.

Venting allows for the cavity air to evacuate as the plastic fills
the mold
Factors Effecting Ejection Force

•Sidewall Draft
•Sidewall Contact Area
•Sidewall Polish/Texturing
•Degree of Packing
•Mold Temperature
•Mold Release
 Mechanical Core Pulls

Line
of
Draw

Slide & Cam action inserts built into a Mold

assembly to eject certain undercuts
 Mechanical Core Pulls

Line
of
Draw
 Mechanical Core Pulls

Line
of
Draw
Plastic Product Design
The Five Design rules

Rule-1
 Use uniform wall thicknesses throughout the part.
This will minimize sinking, warping, residual
stresses, and improve mold fill and cycle times.

Poor Design Improved

Design
  Parts should be designed with a minimum wall thickness
Wall Thickness consistent with part function and mold filling
considerations. The thinner the wall the faster the part
 Adv., minimum wall thickness cools, and the cycle times are short, resulting in the lowest
possible part costs. Also, thinner parts weight less, which
 Need of uniform walls results in smaller amounts of the plastic used per part
 Design considerations for Non-Uniform walls which also results in lower part costs.
The wall thickness of an injection-molded part generally
 Coring
range from 2 mm to 4 mm (0.080 inch to 0.160 inch). Thin
 Wall thickness considerations wall injection molding can produce walls as thin as 0.5 mm
(0.020 inch).

Thick sections cool slower than thin sections. The thin section first solidifies,
The need for uniform walls and the thick section is still not fully solidified. As the thick section cools, it
shrinks and the material for the shrinkage comes only from the unsolidified
areas, which are connected, to the already solidified thin section.
Wall Thickness
The need for uniform walls
Non uniform thickness builds stresses near the boundary of
the thin section to thick section. Since the thin section does
not yield because it is solid, the thick section (which is still
liquid) must yield. Often this leads to warping or twisting. If
this is severe enough, the part could even crack.
Wall Thickness
What if you cannot have uniform walls, (due to design
limitations) ?

When uniform walls are not possible, then the change in

section should be as gradual as possible

Transaction of wall thickness

Wall Thickness

Coring can help in making the wall sections thin and uniform,
this eliminate the problems associated with thick and non-
uniform walls.

Thick wall Shrinkage coring Non-uniform coring

and
section warpage walls
The Five Design rules

Rule-2

 Use generous radius at all corners to avoid part

failure, stress concentrations and poor flow
patterns.

Indicate radii at all inside corners to the

maximum which a design will allow. The
outside radius should be equal to the inside
radius plus the wall thickness.
Outer radius(R) = Inner radius(r) +thickness(t)
Radii, Fillets and Corners
 A fillet radius(r) should be between 25% to 60% the
nominal wall thickness or a minimum radius of 0.02 inch
(0.5mm) is suggested.

 The larger fillet radius suggested for load carrying

features.

 Break any sharp corner with at least 0.005 inch

(0.13mm) radius.
The Five Design rules
Rule-3
 Design parts to facilitate easy withdrawal from
the mold by providing draft (taper) in the direction
of mold opening or closing. Click here for injec.molding_m/c
Click here for injec.molding_m/canimation

CLICK ON PICTURE FOR ANIMATED VIEW

Drafts & Parting line
 Drafts (or taper) in a mold, facilitates part removal from the
mold. The amount of draft angle depends on the depth of
the part in the mold, and its required end use function.
 On the surface in the direction of mold opening or closing
a minimum of 1/20 to be specified.
.
 Typically draft angle is 10 with 1/20 on ribs.
Drafts & Parting line
• Where minimum draft is desired due to design limitations,
good polishing recommended and depth should not exceed
0.5 in.
• More draft aids ejection but may generate a material
mass on sections contained in one side of the mold.
• The mold parting line can be relocated to split the draft in
order to minimize it.

Without draft Draft leads material mass P/L relocation

Drafts & Parting line

 For textured surfaces provide an additional draft of 1° min.

per 0.025 mm (0.001 inch) depth of texture to avoid scuffing
and obtain proper release.
 Draft Angle for Textured Sidewall

Additional 1 Degree per Mil in Depth of Texture

Drafts & Parting line
• Parting line consideration depends upon shape and the
function of the part. Specify the mismatch on the parting line
to meet the required function.
Drafts & Parting line
• Redesign the holes in the side walls so that feature can
obtained with shut off, thus eliminates need of side action
mold. The side action mold required at a greater expense in
tooling.

Side-cam activation mold

Drafts & Parting line

REQUIRES
NO SLIDE REQUIRED, NO SLIDE SLIDE IN
MOLD LESS COMPLEX
REQUIRED MOLD
The Five Design rules
Rule-4
 Use ribs or gussets to improve part stiffness in
bending. This avoids the use of thick section to
achieve the same, thereby saving on part weight,
material costs, and cycle time costs.

Ribbing
Gusset
Ribs, Bosses & Gussets
 Design considerations
for Ribs
 Design considerations
for Bosses
 Design considerations
for Gussets
Ribs
• The rib thickness should be less than the wall thickness-to keep
sinking to a minimum. The thickness(w) ranges from 40 to 60 % of the
material thickness(t).
•In structural parts where sink marks are of no concern, rib base
thickness(w) can be 75–85% of the wall thickness (t).
•For appearance parts, where sink marks are objectionable, rib base
thickness (w) should not exceed 50% of the wall thickness (t) if the
outside surface is textured and 30% if not textured.

W = 40-60% of ‘t’

•Click on Picture for

animated view
Ribs
• The rib height : h = 3 to 5 times the nominal wall thickness.
Deep ribs become difficult to fill, may stick in the mould on ejection.
• Typical draft (q) rib is 1 to 1.50. Minmum draft should be 0.50 to aid ejection.
• The intersection at the base of the rib should radii. A fillet radius(r) should
be between 20% to 50% the nominal wall thickness or a minimum radius of
0.15 inch (0.38mm) is suggested.
The radius eliminates sharp corner and stress concentration and improves
material flow.

h = 3 to 5 times of ‘t’

Draft = 0.50 to 1.50

r = 20% to 50% of ‘t’

Ribs
• Spacing between (a) to parallel ribs should be a minimum of 2 X wall
thickness (t)
This spacing keeps the mold from developing a hot blade and cooling
problems.

a = 2x‘t’ min.
Ribs
• At rib intersections, the resulting thickness will be more
than the thickness of each individual rib. Coring should be
used to thin down the walls to avoid excessive sinking on
the opposite side

coring
The Five Design rules
Rule-5
 Bosses are used for the purpose of registration of
mating parts, considerations are equally important.

Boss
Bosses
Bosses are used for the purpose of registration of mating
parts or for attaching fasteners such as screws or accepting
threaded inserts (molded-in, press-fitted, ultrasonically or
thermally inserted).

• Typically Bass OD (D) = 2 X ID(d)

• The wall thickness (w) at the base of boss
should be less than 40 % of nominal wall to
minimize sinking and cycle times.
d R
• Boss height should be less than 3X OD
Gussets
Boss should not be placed next to a parallel wall; instead,
offset the boss and use gussets to strengthen it. Gussets can
be used to support bosses that are away from the walls.
The same design rules that apply for ribs also apply for
gussets.
LIVING HINGE
Living hinges are thin sections of plastic that connect two segments of a part to
keep them together and allow the part to be opened and closed. Typically these
are used in containers that are used in high volume applications such as
toolboxes, fish tackle boxes, CD boxes etc.

• The materials used to make a living hinge are usually a very flexible plastic
such as polypropylene and polyethylene. These can flex more than a million
cycles without failure.

• Besides meeting the design guidelines, the hinges have to be processed

properly. The molecules have to be oriented along the hinge line for the hinge to
have acceptable life.

• As molded the fibers of the plastic are somewhat random in orientation. In

order to orient the fibers to aid in prolonging the hinge life, some or all of the
following practices should be followed:

- The gate location should be such as to allow the plastic to flow across the
hinge for maximum strength.

- As the part comes out of the mold, it needs to be flexed a minimum of 2 times
while it is still hot, for optimum strength
Molding Defects
 1.2.- WHAT IS A HEADLINER OR A ROOF?

FUNTION AND REQUIREMENT.

Hide sheet metal, cable
system and sunroof windows,
because of AESTHETIC.
To avoid the ACOUSTICAL
problems.
Close to door and pillars to
NORMAL ROOF SUN ROOF help the WATERTIGHT.
Requirements of SECURITY
and REGULATION.
MODULAR
HEADLINER In any case, headliners must
(with be acording with Customer
components) Technical Sheet.
 1.4.- HEADLINER ACCESSORIES.

CONSOLE,
SUNVISOR MICROPHONE
HOLD OR CUTS WITH
A METAL FRAME

IN NON VISIBLE
SURFACE:
HEAD-IMPAC,
PUSH-PIN ..., for
example.
LAMP

RAIN SENSOR

THIS HEADLINER
HASN´T GOT
SUNROOF WINDOW
GRABHANDLE
 1.3.- HEADLINER AREAS.

METAL FRAME AREA UNDERCUT AREA

DEEP EMBOSS AREA
(negative area)

CENTRAL AREA

EDGE WRAPPING AREA

(Umbug)

LATERAL AREA
PERIMETER AREA
 2.1. COMPOSITION

GLASSUTEC (95% OF GRUPO ANTOLIN HEADLINERS)

C SUFACE Backing: Paper/ light non woven

Glass Fibre Roving
Thermosetting adhesive

B SUFACE PUR FOAM

Thermosetting adhesive
Glass Fibre Roving

A SUFACE Fabric: Foamed Knitted/ Non woven

ADVANTAGES: -LOW COST. DISADVANTAGES: - LIMITED RECYCLABILITY

-GOOD ACOUSTICAL
ABSORPTION.
-LOW WEIGHT.
-NO CLIMATIC SAGGING.
 2.2. MANUFACTURING PROCESS

PU+FABRIC+
B Face Sandwich HOT
MOULDING
Fabric cutting Fabric loading

TRIMMING
WATER&
CATALYSER
SPRAYING
Chief of the line
GLASS
FIBER RACK
ROVING

B face material B face material L

cutting loading N TI A
FI DE
N
CO
ADHESIVE
ROLL COATING
1 STEP: PU Loading PU cutting PU foaming

(only 1 MOULD).
 Upper door
substrate
Upper door
skin
Upper foam
block Bolster
substrate
Bolster
skin
Outer sheet
5-Gang
metal panel
Switch
Arm rest skin
Arm rest substrate
Lower foam block
EXPLODED VIEW OF CD 338 FRONT DOOR
 Sail panel
Front Door glass
Remote
handle
Switch
Inner sheet bezel
metal panel
Speaker
Upper door
substrate Map pocket
Bolster Arm rest
Lower door
substrate
CD 338 FRONT DOOR
 Structural Tests
SIDE, FRONTAL, POLE IMPACT TESTS - VIDEOS
 Structural Tests

300N door opening

direction

Vertical
Door Frame
stiffness
 Structural Tests
300 N
300 N

500 N in
the latch
Test 1: Vertical stiffness Test 2: Door Frame Front Test 3: Door Frame Rear

50 N 50 N 470 N

Test 4: Compression Test 5: Traction Test 6: Aerodynamic load

 Door Trim Module Description

Sealing system:
- Sealing joint all around the door trim panel.
- Every mobile piece has a seal joint.
- The sealing concept is validated and in the market.

Sealing joint all

around the door trim
 Door Trim Module Description

Medallion:
- Low pressure injection technology.
- Cover with fabric.
- Integration of the clip’s in the medallion part.
 Door Trim Module Description

Door trim support:

Integrated clip’s for

the harnesses

Loudspeaker
cover Latch
support
 Door Trim Module Description

Door trim support:

Integrated
fixing system
for the door
trim

Fixation for the

window lifter
motor

Reinforcement in
the middle part of
the door trim Plastic
padding Door sheet
metal
 Door Module Experience
Renault Megane Platform
Sealing

Latch

Loudspeaker

Exterior Handle
Window
regulator
 Door Module Experience
Renault Megane Platform
Sealing

Latch

Exterior
Handle
Loudspeaker

Side Impact
Bolster

Window Regulator
 Sealing Validation

Vibration leakage test:

 Door Module
Market Evolution
Conventional Metallic or plastic Door Trim Module
door carrier (AGT) (DTM)

4 planes 3 planes 2 planes

 Door Module
Market Evolution

+
Door Trim Module
New Door Concept
 Door Module
Market Evolution

Structural Module
“Smart” Vehicle Door

Metal Carrier

Door Trim Module

Trim Panel as components
carrier
Plastic Carrier
 Door Module
Market Evolution

Door Module - Frame Concept

Components Carrier
 DOG HOUSE &PUSH PINS

Push pin

Lower substrate
dog house

The substrate is attached to the sheet metal with the help of

push pin which seats on the dog house provided on substrate.
 Provisions for heat stake to
Upper substrate.
Provisions for heat
stake to the bolster.

Dog house to
Assemble into
Door trim panel
Provisions for heat stake to
the map pocket.
FRONT DOOR LOWER SUBSTRATE
Types of attachment features in doors.

Heat staking
Dog House
Snap Features
Screws, U-nuts and etc.
 Side&Rear view
mirror switch

Mirror operating switches

Central locking switch

Switch bezel is a housing which accommodates

window operating switches, mirror switch and
central locking.
 STORAGE SPACE
IN MAP POCKET

Map pocket is a storage unit where you can keep

maps, magazines and etc.
Door sheet metal panel is an inner and outer panel
which is spot welded and clinched.

Outer sheet metal

Inner sheet metal panel

 Safety Study

Padding: Pelvis.
- Material characterization: Plastic padding.
- Characterization with the door trim.

Simulation video. Experimental set-up.

 Safety Study

Padding:
- Material characterization: Plastic padding.
- Individual characterization.

Simulation video. Video of experimental test.

 Safety Study
Crash tests performed: Side crash.
- European normative.
- Volvo S40.
- Focus on door behavior - On-board cameras.
 Safety Study

Crash tests performed: Frontal off-set.

- European normative.
- Renault Clio.
 Sealing Validation

Spray water and dust test:

Water spray
nozzles