Plastic Product Design Principles

Marc Freebrey
Tuesday 11th September

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The right tool ?

1810 1855
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Plastic Product Design Principles

Molded components have changed the shape of everyday items
Lighter Recyclable Aesthetic Design

3D CADCAM systems have facilitated the evolution of product design, and as a result, ever increasing geometry complexity . . . . .

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Consuming Industries
CIMData commissioned an International Trade Report listing the major consuming industries for plastic injection molds. One specific study was to determine the amount of CAD data cleanup work was required by the toolmaker .
Consuming Industry
Motor Vehicles Electronics Appliances Packaging Medical Toys All Other Total

Market Share (%)

41 16 14 10 6 4 9 100

Extent of model modification / clean-up

Substantial Moderate Slight None Total

(%)
21 26 37 16 100

Source : CIMData

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Complexity v's Manufacturability

The objective is to look at some key product design principles that will eliminate uncertainty and ensure manufacturability for your next project. While each of the points are generic and cannot be applied to every scenario, they provide a solid base from where to start your next design. Consistent Wall Thickness

Draft Angle
Boss Design Rib Design Part Radii

Part Text
Undercuts Living Hinges Ventilation Slots

Gate Position
Material Choice
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Consistent Wall Thickness

Consistent wall thickness produces even material flow during the injection phase of the molding cycle, helping to ensure uniform cooling and minimize warpage. Any major change can cause molding issues such internal voids, surface sink marks, unpredictable shrink rates and ultimately, longer cycle times.

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Consistent Wall Thickness

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Draft Angle
Draft angle is an important feature that allows a molded part to be extracted from the mold cavity without issue. The high pressures of injection moulding and material contraction means that it is often difficult to remove the part.
For smooth surfaces, generally a minimum of 1 degree per side provides easy ejection. Textured surfaces are slightly different as the non uniform texture will drag and scuff if insufficient draft is applied.

As a general guideline, a minimum of 1.5 degrees per 0.025mm depth of texture needs to be allowed for - in addition to the normal draft amount.

4 Draft 3 Draft 2 Draft 1 Draft

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Boss Design #1
Bosses are common features in plastic part design as they offer strengthening properties and provide alignment during assembly.
The boss thickness should be 60% of the nominal wall thickness. The boss height should not exceed 2.5 x the diameter of the hole in the boss. Corner bosses integral to side walls will result in excess material accumulation Tall ribs on a boss help material flow and venting, reducing the chances of air traps Gussets distribute the load applied (during screw/insert insertion) to a wider area, reducing failure at the boss/wall junction

Tall ribs on a boss help material flow and venting, reducing the chances of air traps

The top of the boss can cause an air trap and create a short fill or burn mark as a result

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Boss Design #2
Try to avoid bosses that merge into the side walls as this produces thick sections, material accumulation and ultimately, sink marks. If the boss wall thickness must exceed the recommended value, adding a recess (0.3 nominal part thickness) at the base of the boss will reduce the chances of sinking.
Avoid bosses that merge into the side walls as this produces thick sections

Recess to be 0.3 of part thickness to reduce the possibility of sinking

0.3 T

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Rib Design
When creating rib patterns, it is important to remember that ribs are there to increase part rigidity and should not be compromised for aesthetical reasons.

Rib thickness should be 60% - 80% of the nominal wall thickness. Maximum rib height should not exceed 3X the nominal wall thickness. To increase product rigidity, it is better to increase the number of ribs rather than the rib height. Minimum spacing between ribs should be 2X the nominal wall thickness. Fillets at the rib base reduce stress, fillets at the top can aid material flow and minimise sticking within the mold (Fillet radii applied to ribs should be no greater than 50% of the rib thickness). Cross ribbed patterns are preferred (if the design allows) as they offer greater stability and ensure uniform stress distribution. Extra thick ribs should be cored out.
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Part Radii
A significant number of plastic parts fail due to sharp corners or insufficient radii. Sharp corners create localised stress concentrations which will crack and cause premature part failure. The addition of fillet radii to all sharp corners will not only reduce stresses, but also improve plastic flow. As a general rule, at corners, the inside radius is 0.5 x material thickness

and the outside radius should be 1 x material thickness plus the part thickness - a larger
radius should be used if the part design allows it.

Excess material accumulation may lead to voids or sink marks

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Part Text Up or Down ?

Text is usually one of the smallest details on a part and this makes it difficult to manufacture (typically electrodes are required). Text should be embossed (upwards on the model) as this represents a cavity in the mold and therefore easier to machine and easier to polish.

Text should be raised on the part with a minimum of 2 degrees of draft

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Undercuts
Most undercuts cannot strip from the mold and therefore require additional mechanisms in the mold to move certain components prior to ejection. This is typically performed using slides, cams, lifters or collapsible cores all adding costs to the mold design. Clever part design or minor design concessions often can eliminate complex mechanisms for undercuts.

Lifter required for internal fixing on the underneath of the part

Slide required for the holes on the side of the part

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Undercuts #1 Snap-fit
Considerate part design can add value to the component with minimal impact on tooling costs.

Side action required

Draw direction

A core pin eliminates the need for side action when creating snap-fit clips

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Lifters

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Undercuts #2 Side Holes

Considerate part design can add value to the component with minimal impact on tooling costs.

Draw direction

Extending the slots over the top of a corner edge enables straight draw and eliminates the need for side action

Shielded ventilation slots protect internal circuitry

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Creative Fixing
Alternative solutions to the same problem can have a dramatic impact on the part & assembly costs.
Location is guaranteed with fixture fitting

The fixing screw adds part costs and assembly time

PC Board is anchored using snap-fit clip

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Living Hinges
A living hinge is a thin flexible hinge made from the same material as the two rigid pieces it connects. Polyethylene and Polypropylene are considered to be the best resins for living hinges, due to their excellent fatigue resistance and can flex more than a million cycles without failure. The thickness of a living hinge should range from 0.25 to 0.5 mm

1.5mm 0.2mm

R 0.1mm 0.3mm

R 0.75mm

Section showing suggested living hinge design for Polypropylene & Polyethylene

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Source : Efunda.com

Gate Location / Plastic Flow Front

The gate location ultimately determines the filling behaviour, weld lines, shrinkage, warpage and surface quality of the molded part. It is often preferred to gate onto the thickest section of the component to reduce the possibility of sinking due to insufficient material packing.
Features that are normal to the material flow direction will cause weld lines, back fill and unpredictable shrinkage

Material flow following the feature direction

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Gate Location / Plastic Flow Front

Flow Leader Thickened sections (no more than 25% of nominal part thickness) to help drive the plastic flow front. Typically used for filling or packing issues in areas furthest away from gate location or used to balance the filling of non symmetrical parts Flow Restrictor Small areas of reduced thickness (no more than 33% of nominal part thickness) to help control the plastic flow front. Typically used to control the filling pattern and manage weld lines and air trap locations.

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Accepted Technology

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Material Choice
Successful designs are built on the knowledge of how the chosen resin will perform during the molding process
Material / Resin Strength Impact Resistance
Medium High Medium High High High

High Temp Strength

Medium / Low Low High Low Low Medium / High

Warp and dimensional accuracy

Fair Fair Poor Fair Fair Good

Fills small features

Fair Excellent Good Excellent Excellent Fair

Voids in thick areas

Poor Good Excellent Poor Unknown Fair / Good

Sinking in thick areas

Good Fair Good Poor Poor Fair

Acetal Nylon 6/6 Nylon 6/6, Glass Filled Polypropylene High Density Polyethylene (HDPE) Polycarbonate

Medium Medium High Low Low Medium

Acrylonitrile Butadiene Styrene (ABS)

Polycarbonate / ABS Alloy Plybutylene Terephthalate Polystyrene Thermoplastic Elastomer Acrylic

Medium / Low
Medium Medium Medium / Low Low Medium

High
High High Low High Low

Low
Medium Low Low Low Low

Good
Good / Excellent Fair Good Poor Good

Fair
Fair Fair Good Excellent Fair

Good
Good Unknown Unknown Excellent Excellent

Fair
Fair Fair Fair Good Good

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Source : Protolabs

Trouble Shooting
Problem
Brittleness
Wet material Overheating Molded-in-stresses Poor part design Weld-lines Review drying procedure Reduce barrel/nozzle temperature Increase barrel/nozzle temperature Eliminate sharp corners Increase injection pressure Increase melt temperature

Cause

Remedy

Problem
Weak weld-lines

Cause

Remedy

Insufficient venting Injection speed or mold temperature too low Incorrect gate location

Improve cavity venting Increase injection rate and tool temperature Relocate gate or add overflow tab

Sticking in mould
Over packing Mold design Reduce injection pressure Reduce injection speed Check for undercuts Inspect ejector system Increase draft in tool

Warped parts
Part temperature differential Excessive shrinkage Orientation of material Poor part design Ejection problem Check mold cooling system Increase part packing Change gate location Add ribs or part thickness to improve stiffness Check for uniform wall thickness Increase cooling time Reduce mold temperature Increase ejector pin area

Sinks or voids
Holding pressure / time too low Insufficient feed Gate freezing off or located improperly Increase hold pressure or time Increase shot size Check gate dimension and location

Flashing
Inadequate clamp tonnage High Injection Pressure Misaligned plates Excessive vent depth Use a larger machine Reduce injection pressure Align plates Review mold venting

Dimensional inconsistency
Shot to Shot variation Melt temperature variation Inadequate packing Maintain adequate cushion Check for worn check ring Check heater bands/controllers Increase hold time Enlarge gate to prevent premature freeze-off

Burn marks
Air trapped in cavity Barrel or nozzle overheating Shear heat Contamination Hang-up in molding machine Improve mold venting Check heater controls Reduce injection speed Purge barrel Clean hopper dryer Remove and clean screw

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A project

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Automotive Instrument Panel

Specifications: Part weight 2.9 Kg 10 Injectors Manifold

Injection Time 60 s
2300 Tons Injection Machine 32 Tons mold

600 Parting Surfaces 54 Modified Areas

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Injection Side Mechanics

10 undercuts on the injection side

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Ejection Side Mechanics

21 undercuts on the ejection side

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Cooling

36 different cooling circuits

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Vital Statistics

Numbers:

5740 Solids
1348 Screws 685 Cooling Channels

6 Part Changes
486 Hours (Design time) 3 Concurrent Designers

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Conclusion
Understanding the mold design & manufacturing
process will help you design better parts. Check List :
Uniform Wall Thickness Adequate Draft Fillet Wherever Possible Basic Rib Fundamentals Basic Boss Fundamentals Understand Material Characteristics Knowledge Sharing Relationship With Molder
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Thank you for your time & attention

Come and see us @ E-3114

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