From Art to Part 2009 Plastics Part Design

By: Sidney Wong & KM Ho Tel: 27667616, 27667620 E-mail: icsidney@polyu.edu.hk ickmho@polyu.edu.hk

Intended Learning Outcomes

After completing this training session, YOU are expected able to:

Address the key design concepts for thermoplastic part design List out the common thermoplastic part assembly methods , select and applying them in the group project Apply general plastic design rules/ simple calculation in designing a thermoplastic product

General Design Rules of Injection Moulded Moulded Part

Uniform wall thickness Part Geometries Draft Angle Radii / Fillet Structural Ribs Design Bosses Snap-Fit Design

Uniform Wall Thickness (UWT)

Why Uniform Wall Thickness is important in plastic part design? Non-uniform and/or heavy wall thicknesses can cause serious warpage and dimensional control problems in the injection molded products. Heavy wall sections cause not only internal shrinkage, voids, and surface sink marks, but also non-uniform shrinkage resulting in poor dimensional control and warpage problems.

Uniform Wall Thickness (UWT)

Uniform Wall Thickness (UWT)

RIBS

How to achieve UWT

Coring should be employed where possible to eliminate material masses in the part. When wall thickness transitions cannot be avoided, the transition should be made gradually, on the order of 3 to 1.

Part Geometries
Although UWT is achieved, sometimes the part geometries itself will generate moulding problems

Part Geometries

Task 1
Try to modify below part geometry to improve the manufacturability

Draft Angle
Draft angles for internal and external walls are essential to the ejection of the moulded parts from the mould. External walls require smaller draft angles than the internal walls.

Draft Angle

Minimum Draft Angle

External Wall W/O Texture Depth < 1 0 15 to 0 30 W/ Texture Internal Wall W/O Texture W/ Texture (0 30 to 1) +

(0 15 to 0 0 30 to 1 30) +

Depth > 1

1.0 to 1.0 30

(1.0 to 1.0 30) +

1.0 30 to 3.0

(1.0 30 to 3.0) +

Radii / Fillet
Internal sharp corners and notches are the leading cause of failure in injection moulded thermoplastic parts. To avoid the problem occurred, radii / fillet is commonly employed to all sharp feature

Radii / Fillet

A fillet radius should be between 25 to 60% the nominal wall thickness. The larger fillet radius is suggested for load carrying features

Radii / Fillet
The outside corner radius should be equal to the inside radii plus the wall thickness (R = r + t).

Structural Ribs Design Ribs

Rib is one of the common features used in plastic part design to strength the structure and to reduce the weight of the product.

Structural Ribs Design Ribs

However, for many resins, the use of ribs will produce sink marks on the external surface and this defect becomes very noticeable on the moulded product. There are several resins on the market that have good surface appearance behind the rib area, for example, PVC, ABS, PC, LCP, PBT, PET

Structural Ribs Design Ribs

Structural Ribs Design Ribs

The thickness of the rib at the intersection with the nominal wall should be 50 to 60% of the nominal wall. Maximum rib height: h=3 x nominal wall thickness. Typical draft for ribs is 1 to 1.5. Minimum draft should be 1/2 per side. Spacing between two parallel ribs should be a minimum of 2 x wall thickness.

Task 2
Try to integrate the concept of Draft, Fillet & Rips to enhance the design

Bosses
Bosses are thermoplastic cylinders attached to a side wall or end corners. Special self-tapping screws are used to mount other components. The bosss outside and holes inside diameters are based on size, depth and type of screws, pullout torque requirements, resin modulus of elasticity, creep, and boss weld line strength.

Bosses

Bosses

Bosses
Typically the boss OD = 2 ID. The wall thickness at the base of the boss should remain less than 60% of the nominal wall thickness. The boss height should be less than 3 OD. Draft on the OD is 1/2 and ID is 1/4 Min. Keep the minimum distance of twice the nominal wall thickness between 2 bosses.

SnapSnap-Fit Design
Snap fits are commonly used as an assembly method for injection molded parts. Snap fits are very useful because they eliminate screws, clips, adhesives, or other joining methods. The snaps are molded into the product, so additional parts are not needed to join them together. There are three main types of snap fits: Annular, Cantilever, and Torsional.

http://engr.bd.psu.edu/pkoch/plasticdesign/snap_design.htm

Annular Snap Fit

ASJs are generally stronger, but need greater assembly force than their cantilevered counterparts. Annular Snap Fit are basically interference rings.

http://machinedesign.com/ContentItem/61167/FundamentalsofAnnularSnapFitJoints.aspx

Annular Snap Fit child-proof bottles childThe ridge geometry of the annular snap-fit plug determines the assembly force F needed to engage the joint. A shallow return angle of 30 easily separates while a 90 angle is permanent. Designers of child-proof bottles employ a clever trick to transform a permanent snap joint into one that easily disengages.
http://machinedesign.com/ContentItem/61167/FundamentalsofAnnularSnapFitJoints.aspx

Key points of applying Annular Snap Fit

Dont use cylindrical snap-fits with very stiff materials, making the plug from a more rigid material than its mating female hub. Use an engagement angle of 20 to 30 and a 20 30 release angle of 40 to 50. Place the undercut near the open end of the hub. Size the undercut so that the design stress figure is not exceeded.

Cantilever Snap Fit

Cantilever snap fits are the most widely used type of snap fit. There is a considerable amount of calculation and engineering that goes into designing a good snap fit

http://engr.bd.psu.edu/pkoch/plasticdesign/snap_design.htm

Cantilever Snap Fit

http://engr.bd.psu.edu/pkoch/plasticdesign/snap_design.htm

Key points of applying Cantilever Snap Fit

Keep within the allowable strain figure. If the calculated allowable deflection is too small, try increasing the snap hook length. Design so that the snap hook is no longer flexed after it has clicked into the catch Snap-fits are meant to be used either once or just a few times, so fatigue and wear can be neglected. Radius the root of the snap hook to reduce stress concentration.

Torsional Snap Fit

The torsional snap-fit relies for its spring effect on twisting rather than flexing like the other types. It is a good way of fastening a hinged lid on a box or container.

Key points of applying Torsional Snap Fit

Use torsional snap-fits when you want to be able to release the catch easily. Include a design feature to show where to press. Design a stop feature to prevent excessive torsion. Do not make the catch lever length too short otherwise the twist angle and torsion becomes too great. Reduce the opening force by making the length of the opening lever longer than the catch lever.