Plastic Part Design

Index
1. Plastics materials type
2. Important manufacturing Process.
3. Injection Molding Process Details
4. Design Considerations for Plastics part Design
 Plastics material
Plastics

Themoplastics Themosets Elastomers

Amorphous Semicrystaline
Manufacturing Process for Plastics
Injection Molding
 Blow Molding

1. Extrusion Blow Molding

2. Injection Blow Molding
3. Stretch Blow Molding

Extrusion Blow Molding.

ExtrusionBlowMol
dingVideo
Injection Blow Molding
Stretch Blow Molding

Injection_Blow_M
olding_Video
Thermo Forming

Plastic Extrusion
Comparison of Different Processes.
 Injection Molding Process Details.

For thermoplastics, the injection molding machine converts granular or pelleted raw
plastic into final molded parts via a melt, inject, pack, and cool cycle. A typical injection
molding machine consists of the following major components:

• Injection system
• Hydraulic system
• Mold system
• Clamping system
• Control system

A single screw injection molding machine for thermoplastics

Machine specification
• Clamping tonnage and shot size are commonly used to quickly identify the size of the
injection molding machine for thermoplastics.
• Other parameters include injection rate, injection pressure, screw design, mold
thickness, and the distance between tie bars.
 Tooling for a plastic cup

Nozzle

Knob

Runner
Cavity

Part
Stripper plate

Core
 Nozzle

Nozzle Knob

Runner

Runner
Cavity
Cavity Cavity
Part

Part Part
Stripper
plate
 Plastics Part Design Considerations.

Uniform Wall Sections

Use uniform walls to minimize warp age and maximize manufacturability potential.

Injection Molding : 2 to 4mm

No thick areas - core for uniform sections.
Always try to core from the ejector side of part.
 Draft Angles
Draft is needed to facilitate release of part from mold.

The draft to use, unless otherwise specified, is 1 to 1.5 degrees per side.

Indicate if draft is to be added or subtracted from nominal dimension.

Show draft on part whenever possible to avoid confusion as to direction.

The "No Draft Allowed" is not to be used. Even on critical areas allow 0.5 degrees.
 Undercuts
1. External Undercut
2. Internal Undercut
injection_mold_cavity_slide.mp4

External Undercut

Internal Undercut
External Undercuts are removed in Mold with Sliders.

SliderActuation
Slide Core

Cover tool

Molded
part
Horn Pin

Locking Block

Undercut

Spring
Slide core
Slide Core
Slide Core
Slide Core
 Design Considerations For External Undercut

1. As far as possible try to avoid the Side action as shown below.

2. Give Drafts for the side action as a shown.

Side action Direction

 Internal Undercut

This types of undercuts are removed in Molds with Lifter .

Lifter_actuation_vi
deo
Internal Undercut
Lifter 　　　　
Lifter

Undercut

Angled pin
Lifter
Lifter
Lifter
Lifter
Lifter
Lifter
Design Considerations
Design For
Considerations
Interal Undercut

1. If Possible, check if Undercut can be avoided ,by providing a Cut in the Tool Movement Direction.

Minimum 5 Degrees Shutoff angle should

be maintained.
 2. No Feature should come in way of Lifter Movement.

a b

c > a+b+3

c- distance between any feature after undercut feature

a- undercut value
b- Lifter Insert width.
3. Surface should not be inclined, otherwise plastics will interfere during the Lifter Movement.
Rib Design t

For Visible parts to avoid Sink marks.

t= 0.4 * T
L<= 3T
Sharp Corner
-Avoid Sharp Corners in Design,
- Sharp corners increases the stress concentration
- Fillet radius provides a streamlined flow path for the molten plastic, resulting in an
easier fill of the mold

- Make sure that no Radius is added at Parting line.

Boss Design
 GUSSET

Gussets adds support to Mechanical Strucutres

 Common Molding Defects

1. Sink Mark-
Sink marks or shrink marks are hollows or indentations that occur on the outer surfaces of
molded components

Design Care-
Maintain Uniform wall thickness on Part,
Maintain Rib to wall thickness Ratio.
 2. Warpage
Warpage is a term used to describe the deformation which occurs when there are
differences in the degree of shrinkage at different locations within the molded
component

Causes-
-Distribution of wall thickness : Areas with non-uniform distribution are included.
-Insufficient structural stiffness : The structural stiffness of ribs and the like is insufficient. Ribs can
actually contribute to warping, and therefore, a detailed examination of thickness and height
factors must be undertaken
3. Flash

4 Short Fill
 5 Weld Line

6. Air trap
7 Flow marks
Thank You