plastic part design guide
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plastic part design guideTo ensure a quality part, there are three major areas of focus throughout the design stage: This guide was designed to demonstrate the basic elements of proper plastic part design. Undercuts on the part cause this blockage of path and require an action in the mold (cams, core pulls, etc.). Action in the mold can have a major impact on the cost (and overall size) of a mold. Plastic shrinks as it cools which can lead to defects such as sink marks, voids, stresses, and warping. Plastic resin solidifies in the mold nearer to the outside of the part (closest to the mold surface). Thick sections of a part tend to pull inward, creating stresses, sink marks, or voids. Since thinner sections cool quicker, stress can build in the part between thinner and thicker sections, resulting in part warpage. Draft is the angle in which the part is tapered to allow it to release. As the part cools, it tends to want to shrink to the core side of the mold. Adding draft helps the part to release.Core pins are typically used to form a hole, preventing the molten plastic from filling in that space. Through holes go all the way through a part. Blind holes do not completely go through a part. Core pins for a blind hole are only supported by one end, so there is a greater degree of difficulty in forming them without defect. Forming holes can lead to defects or have a negative impact on aesthetics.Improper placement of a boss leads to uneven wall thickness and can have a negative impact on the aesthetics, shrinking, or strength of a part. Adding ribs allows for a part to increase strength and bear a higher load. Ribs too have recommended guidelines to maximize functionality and minimize defects. Recommended thickness is 60 to 80 of the nominal wall. It is better to add more ribs than make larger or thicker ribs. Corners can lead to stresses, limit material flow, and often reduce part strength.https://ecatts.com/userfiles/cub-cadet-kawasaki-engine-manual.xml
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You can rest easy knowing that API has partnered with resin suppliers for over 60 years and has a multitude of experience in manufacturing plastic parts with even the most difficult-to-process resins. Please see our basic resin guide for a few examples of commodity and engineering resins that API has become an expert in molding. Site by Innovative Images. API specializes in working with difficult to process, engineering resins and high percentage glass filled materials. API is a full service custom plastic injection molder that works with customers to design and develop new products, engineers prototypes, builds molds, and manufactures plastic parts all under the same roof in Long Island, NY. The Autronic Plastics team works to improve client product ideas and helps to design plastic products for manufacturability and cost efficiency. Our engineers become a valuable extension of your product development team. Jaycon Systems got you covered with our design, engineering, and manufacturing services. We are Jaycon Systems, a team of geeks who got together to bring people’s product ideas to life. We are passionate about making things, but we also love the technologies that enable us to make these things. In the world of making things, there are many ways to manufacture products. If these products are made out of plastic, there are numerous ways we can mass produce them: casting compression molding extrusion fabrication foaming injection molding rotational molding thermoforming At Jaycon Systems, we have chosen to use injection molding as the main manufacturing process to bring plastic products to life. However, injection molding is not simple. Engaging in such process requires an extensive knowledge about its machinery and process. But before we get started, make sure you get your free Injection Molding Design Tool to follow along with this article — see for yourself how these design aspects translate into plastic pieces.http://nestuby.com/userfiles/cub-cadet-lawn-mower-engine-manual.xml Injection molding is the technique where molten plastic is injected into a metal mold. The mold is composed of two halves, the “A” side and “B” side. The halves are separated and allow the plastic component to be removed once it has solidified, thus creating plastic parts. Part A and Part B make up injection mold halves illustration What should we keep in mind when designing for injection molding. Draft Angles Draft angles allow for removal of the plastic from the mold. Without draft angles, the part would offer significant resistance due to friction during removal. Draft angles should be present on the inside and the outside of the part. Green illustration shows correct draft angle and red shows a lack of draft angles The deeper the part, the larger the draft angle. A simple rule of thumb is to have a 1 degree draft angle per inch. Radiused Edges Having radiused edges and corners (both inside and outside) of a part is a multipurpose feature. This allows for better removal during part ejection, — in conjunction with drafted sides — and better material flow (more on this later). Most importantly, however, is that it will not only prevent excessive expenses when creating the mold, but it will prevent cracks from forming due to stress concentration. Undercuts can appear just about anywhere in the design. These are just as unacceptable, if not worse than a lack of a draft angle on the part. Illustration shows acceptable undercut due to sliding portion of the mold Keep in mind that creating undercuts is more costly when producing the mold and should be kept to a minimum. Solid vs Shell As the plastic cools in the mold, it also shrinks, which is a common characteristic for most materials. Making a component a shell versus a solid helps reduce the amount of shrinkage or warpage that happens during the cooling process. It also helps lowers the cost of material needed to be used in that part.http://www.bouwdata.net/evenement/boss-audio-bv-7970-manual There are numerous ways to shell a design, one example is shown on the sphere below. Example of a solid design (left) prone to shrinkage and warpage vs. These marks are caused by a number of items: inconsistent wall thickness (may also lead to voids); bad radius in corners; thick support ribs (to be discussed later); sharp corners; not shelling parts out. They are used mainly in two situations: (1) where the part has 90-degree angled walls that meet, and (2) where a part may be too long or large and the wall thickness leaves the part flimsy or weak. Support ribs tend to work best in the direction in which they are needed, such as running the length of a long section. Red illustration shows incorrect direction of support ribs and green illustration shows proper direction of support ribs When designing support ribs, it is important to consider draft angles and base thickness at no more than.Connecting Parts Together Products are generally composed of two or more parts connected together. These parts can be connected with mounting bosses, snap hooks, screws, etc. A common way of uniting two parts is using screws through mounting bosses. Part Lines Part lines are where the two halves of the mold meet. This generally creates a physical line on a part that is both visible and noticeable to the touch. These lines, however, can be hidden or minimized when placed along edges of the part. When designing a part, always keep in mind its part lines. Example of a part line on a screwdriver Illustration shows where part lines occur in the mold Ejector Pin Locations Ejector pins are what allow the part to be removed from the mold. These pins literally push the part out after the material has been injected into the mold and set. However, while pushing parts out, these pins leave marks on the part. These marks are generally not removable, so location is key to keep in mind when designing the part.http://hermandadtropasnomadas.com/images/carburador-manual.pdf Arrows point to ejector pin marks on a battery holder plastic enclosure Illustration shows where ejector pin marks happen due to ejector pins (grey) pushing pieces out Gate Locations and Material Flow Along with ejector pin locations and part lines, it is also important to know where to have the gate locations. Gates are where the molten plastic enters the cavity of the part in the mold. Gate location is sometimes determined by: where it will be less noticeable; where it will not interfere with the rest of the part; how the plastic material will flow evenly through the part; or a combination of all these. Although harder to see, gate locations should be strategically placed due to its prominance as shown in the picture Gate location is shown in this illustration where it is separated from the plastic piece Material and Thickness Depending on (1) how the product works, (2) the environment it will be in and (3) the preference of the designer, a material should be selected. These materials change how the part feels, looks and operates. Some are flexible, some are rigid, some are strong, some are brittle. The type of material chosen will often have a significant effect on the design of the part. Some support ribs may need to be removed or added, walls may need to be thicker or thinner, etc. Wikipedia article shows sample picture of support ribs on a plastic part to strengthen the design Recommended Wall Thickness Conclusion All the concepts presented in the previous slides make up just some of the good practices an engineer has to keep in mind when designing parts to be mass manufactured by means of injection molding. These practices are also known as DFM (Design For Manufacturability) and should be used as a checklist constantly throughout the design and redesign of products. Remember, keeping these practices in mind will ensure long-term savings in manufacturing costs and time for customers. Need injection molding services. Jaycon Systems got you covered, check our services here. Want the presentation version of this article. Check this link for an awesome slideshow. We love sharing AND SO SHOULD YOU. We can help because what you just saw is what we love to do. Think we missed something. If you would like to add to this article, send us a message and we will do our best to include it to our post. Our offerings range from product and electronics design to prototyping and manufacturing. With our entrepreneurial spirit and as a rapid-prototyping firm, we believe in building products right the first time and introducing them quickly to market. Follow Written by Jaycon Systems Follow We bring your product idea to life: from ideation and prototyping to manufacturing and fulfillment. www.jayconsystems.com Jaycon Systems Follow Jaycon Systems specializes in bringing hardware products to life by offering a complete service line that takes product concepts to mass production. Jaycon Systems in Jaycon Systems The Misery of the No-Spend Year John McDermott in MEL Magazine Invincibility Is an Illusion That Will Not Sustain Us Rev. Sheri Heller, LCSW in Publishous Learn more. Medium is an open platform where 170 million readers come to find insightful and dynamic thinking. Here, expert and undiscovered voices alike dive into the heart of any topic and bring new ideas to the surface. Learn more Make Medium yours. Follow the writers, publications, and topics that matter to you, and you’ll see them on your homepage and in your inbox. Explore Share your thinking. If you have a story to tell, knowledge to share, or a perspective to offer — welcome home. It’s easy and free to post your thinking on any topic. Write on Medium About Help Legal Get the Medium app. These will help you design parts that can be molded without issues and meet the requirements with respect to structural performance, weight, cost and aesthetics. They are available in a broad range of base polymers and can be tuned to meet specific requirements by including additives. Depending on the plastic concerned, the benefits of thermoplastic materials include their high strength to weight ratio, non-conductive properties, flexibility and chemical resistance. By applying these guidelines consistently, the result will be a part that can be mass-produced smoothly and lives up to the expectations in terms of dimensions, properties and appearance. Coring, locally eliminating material in these sections, is a way to pursue a uniform wall thickness. It has various advantages compared to other plastic manufacturing processes. Following plastic part design guidelines for injection molding ensures good quality manufactured parts. In this article we will discuss various plastic part design guidelines for injection molding. Table of Contents Why to follow Plastic Part Design Guidelines for Injection Molding. Plastic Part Design Guidelines 1. Uniform Wall Thickness in Plastic Parts 2. Plastic Boss Design Guidelines on Plastic Parts 3. Reinforcing Rib Structure Design in Plastic Parts 4. Sharp Corners in injection molded Plastic Parts 5. Gussets In Plastic Parts 6. Draft Angle in Injection Molded Plastic Parts Why to follow Plastic Part Design Guidelines for Injection Molding. Plastic part design plays a very important role in ensuring injection molded plastic part quality. If plastic part design is as per guidelines, Relatively better injection molding window can be achieved. Therefore more variation in the injection molding process can be accommodated. But following all plastic part design guidelines for injection molding does not guarantee best quality parts. Therefore it is always recommended to also control mold design and injection molding process to manufacture quality plastic parts. Following factors affect the quality and consistency of injection molded plastic parts. Plastic Part Design Plastic Material Process Parameters Injection Molding Machines Injection mold Design Plastic Part Design Guidelines Although it is not possible to follow all design guidelines because of product design constraints. But it is recommended to follow as much as possible to achieve defects free plastic parts. If the plastic part design is not as per guidelines. It is recommended to do simulation studies (mold flow analysis for plastic parts) to reduce the risk. Following injection molding plastic part design suggestions have a huge impact on manufactured plastic part quality. Uniform Plastic Part Wall Thickness Plastic Boss Design. Rib Design Recommendation. Sharp Corners Gussets Draft Angle 1. Uniform Wall Thickness in Plastic Parts Uniform wall thickness in injection molded parts ensures molten plastic is not forced through varying restrictions during injection molding. Therefore it allows the injection mold cavity to fill more easily. How Uniform Wall Thickness Will Improve Plastic Part Design. When molten plastic is injected into injection mold with variable part cross-section. The thin plastic section starts cooling first. But when the thick section starts to cool. Part shrinks and stresses are built up near thin and thick section boundary areas. Because the thin section has already hardened, it doesn’t yield. Therefore when the thick section yields, it leads to warping, twisting, shrinkage or void formation in the part. High stresses can also cause cracks in molded plastic parts. Design Guidelines for non-uniform Plastic Part Wall Thickness In design, it’s not feasible to provide uniform wall thickness in all sections. Therefore following points are recommended to reduce the impact of non-uniform wall thickness. Recommendation for Non-Uniform Plastic Part Thickness Gradual change in plastic part wall thickness. Avoid filling molten plastic from thin to thick sections. Remove plastic from thick sections (coring). Analyse flow of molten plastic in thinner sections. 2. Plastic Boss Design Guidelines on Plastic Parts It consists of a cylindrical projection with holes. During product life-cycle bosses are subjected to various loads. Therefore Boss design in plastic parts should be as per guidelines to ensure boss strength and avoid injection molding defects in plastic parts. Boss Wall Thickness Recommended boss wall thickness is 0.6 times of nominal wall thickness of the plastic part. For example, in case of high stresses produced while using self-tapping screws. But this will have an impact on part aesthetics. Radius at Boss Base Small radius at the boss base increases boss strength and also helps in part ejection during injection molding. Thick sections are very difficult to cool and result in injection molding defects. Therefore it is recommended to maintain minimum spacing between bosses. Its Value depends on surface finish and boss height. Mostly 0.5? to 1? draft is recommended in boss section. Other boss Design Requirements Boss strength can be increased by providing gussets at the base or by using connecting ribs to nearby walls. If the boss-wall thickness is more than recommended thickness. As shown above, Recess around the base of the boss is provided to reduce the probability of shrinkage 3. Reinforcing Rib Structure Design in Plastic Parts Ribs in plastic parts increase the part moment of inertia by increasing the bending stiffness. Therefore Ribs are used in plastic parts to increase bending stiffness without increasing plastic part thickness.Recommended minimum distance between two ribs is two times of nominal wall thickness. It is required to avoid large variation in rib thickness. To increase bending stiffness, Multiple ribs are recommended instead of one large rib. Maximum Rib Height (H) Sharp Corner Radius Sharp corners at rib base results in stress concentration. A minimum radius equal to 0.25 times of nominal thickness is recommended to avoid stress concentration after injection molding. Rib Intersection in injection molded Part Coring out rib at rib intersection is recommended to avoid excessive sinking on the opposite side of the rib. Rib Orientation Recommendation A rib is oriented in such a way, it provides maximum bending stiffness to the part. Rib orientation depends on part geometry and bending load. 4. Sharp Corners in injection molded Plastic Parts Sharp corners in plastic parts can lead to high stress, restrict material flow, and reduce part strength. Therefore it is recommended to add Radius in plastic part design for injection molding. Recommended inside corner radius in plastic pat design is more than 0.5 times the nominal wall thickness. Whereas recommended outside radius is inside radius plus nominal wall thickness. If the ratio of the radius and thickness is less than 0.5. Stress concentration factor is considered high. But the location of gussets prevents direct venting in mold steel. Therefore Gussets in plastic parts should be designed in such a way that it should not create any venting or filling problems. 6. Draft Angle in Injection Molded Plastic Parts Draft Angles are provided parallel to the direction of part release. It helps in easy removal of plastic part from injection mold. Higher the value of draft angle. Easy will the removal of part from injection mold. Industrial designers will always ask for zero draft but mold designers need max possible draft angle. Polished plastic parts require relatively small draft angle compared to matte finish parts. It’s not feasible to follow all design guidelines. But wherever guidelines are not followed, It is good to reduce the risks by performing simulation studies. We will keep updating injection molded plastic part design guidelines. If you need any support or have questions on plastic part design. Write us in the comment box. Heat Sink Thermal Resistance and Size Ca. Two Plate and Three Plate Mold Tolerance Stackup Analysis: Worst Case. What is Factor of Safety in Design and H. What is Electron beam Welding Process. What are different types of Metal Extrus. Screws for Plastic: Self Tapping Cuttin. Mechanical Design Interview Questions an. Heat Sink Thermal Resistance and Size Ca. Two Plate and Three Plate Mold Tolerance Stackup Analysis: Worst Case.Shopping Basket If you continue to use this site we will assume that you are happy with it. Ok Privacy policy. It has various advantages compared to other plastic manufacturing processes. Setting up a conference call Wi-Fi Calling Internet calls Using Call log Using Home dialing Call services Turning Airplane mode on or off Messages Opening Messages Sending a text message (SMS) Sending a picture message (MMS) Resuming a draft message Viewing and replying to a message Forwarding a message. A note often gives additional information, such as what happens when you choose to do or not to do a certain action. A note also provides information that may only be applicable to some situations. Make sure to switch off myTouch 4G Slide before removing the back cover. 1. Turn off myTouch 4G Slide and hold it securely with the front facing down. 2. You’ll hear several clicks as you press the back cover to indicate that it is being secured in place. Inserting the SIM card 1. Take the back cover off. 2. Remove the battery. 3. With the SIM card’s gold contacts facing down and its cut-off corner facing out, insert the SIM card all the way into the SIM card slot. You’ll find the storage card already inserted in myTouch 4G Slide. Inserting the storage card 1. Take the back cover off. 2. Insert the microSD card into the storage card slot with its gold contacts facing down and push it until it clicks into place. How long the battery can last before it needs recharging depends on how you use myTouch 4G Slide.Before you turn on and start using myTouch 4G Slide, it is recommended that you charge the battery. A thin film is inserted between the battery and the compartment. Facebook Log in to your Facebook account through Facebook for HTC Sense to import your Facebook friends' contact information. Phone contacts You can choose to create and store contacts directly in myTouch 4G Slide or transfer existing ones from your old phone. You can customize the Home screen by adding widgets, favorite applications, shortcuts, and folders so they’re always just a tap away. To find out how, see Personalizing on page Extended Home screen. It reveals all five Home screens as thumbnails. Just tap the one you want and you’ll leap right there. It also stops accidental button presses when myTouch 4G Slide is in your bag. You’ll still receive messages and calls though.The Notifications panel lets you quickly switch between recently-opened apps, and also lets you easily turn on settings such as Wi-Fi and Bluetooth. Selecting text 1. Press and hold on a word. 2. Drag the start and end markers to highlight the surrounding text you want to select. Tap Advanced to set the page size, print layout, and page orientation, and choose if you want to print in color or black and white. 5. Personalize it with a different wallpaper, ringtone, and notification sound for events such as incoming text, email, and calendar reminders. From the Home screen, press and tap Personalize to get started. Slide your finger on the screen from right to left to view the different styles, and then tap Select to choose one. You can also add shortcuts to settings and specific information such as a bookmarked webpage, someone’s phone number, a music playlist, route directions, and many other items, to your Home screen. Don’t lift your finger just yet. 5. Drag the app icon or shortcut and drop it on top of the folder. Simply tap the folder to open it so you can access the apps and shortcuts inside the folder. For example, move the panels with frequently-used widgets, shortcuts, and folders closer to the main Home screen. The center thumbnail in Leap view is always the main Home screen. 1. For example, if you assign a contact’s number to the number 2 key, you can just press and hold 2 to dial the number. When a call is in progress, use the buttons onscreen to mute or unmute the microphone or to turn the speakerphone on or off. You can also press and choose whether to add a call, place the call on hold, mute the microphone, and more. Putting a call on hold 1. Turning on Wi-Fi Calling Make sure that myTouch 4G Slide is connected to a Wi-Fi network before you turn on Wi-Fi Calling. Adding an Internet calling account Before you add an Internet calling account, make sure that you've registered with an Internet calling service that supports voice calls over Session Initiation Protocol (SIP). Checking a missed call You will see the missed call icon in the status bar when you miss a call. 1. Slide open the Notifications panel to check who the caller is. 2. Your home country code is automatically added when you make calls while roaming. 1. On the Home screen, tap 2. Enter the phone number from your home country that you wish to call. If you enter a leading zero, it will be removed. Home dialing Set the country code to be automatically added before the phone numbers you dial while you're roaming. TTY mode Enable TTY (Teletypewriter) support for your phone. Call forwarding Select how you want to handle busy, unanswered, and unreachable calls. Use the Messages app to compose and send text (SMS) and picture messages (MMS). The Messages screen opens, where all your sent and received messages are neatly grouped into conversations, by contact name or phone number. If you exceed the limit, your text message will be delivered as one but will be billed as more than one message. Picture Take a photo and attach it, or attach an existing photo. Video Record a video and attach it, or attach an existing video. Audio Make a voice recording and attach it, or attach an existing audio file. A new message icon is also displayed in the status bar. 1. There’s also a bold letter before the phone number to indicate the number type (for example, M stands for Mobile). When Auto-retrieve in MMS settings is disabled, only the message header is downloaded. Deleting several messages within a conversation 1. Some applications, such as Contacts or Mail, have their own search function, which you can use to search only within those applications. Apps downloaded from the Web can be from unknown sources. To protect myTouch 4G Slide and your personal data, we strongly recommend that you download and install only apps you trust. Viewing a previously visited page 1. While viewing a webpage, press, and then tap Bookmarks. 2. You can choose to view the full version of all pages, even for these sites.Be sure to plug in your storage card before you start.Tap an area on the Viewfinder screen to display the zoom bar, and then slide your finger left or right on the zoom bar to zoom in or out. Light on Light off 9. To stop recording, tap again. Macro When you're pointing the camera at an object, it auto focuses on the object at close distance. Night (photo mode only) When you're in a low-lit environment, the camera enhances brightness in your photos and videos. When enabled, myTouch 4G Slide renders both the bright and dark areas of your subject. The result: better photos with the right image intensity and contrast levels. 1. Widescreen (photo When this check box is selected (default), photo resolutions mode only) available for selection are in 16:9 ratio and you can use the. Get an audience by tagging your Facebook and Flickr friends. Slide your finger up or down to scroll through the thumbnails. Tap a photo or video to view it in full screen. While viewing a photo in full screen, you can press, and then tap Show on map to see the location where you took the photo. You’ll see a crop box around the photo. 4. To adjust the crop box size, press and hold the edge of the box. 5. When directional arrows appear, drag your finger inward or outward to resize the crop box. As you drag a slider, you'll see time markers and video frames. The one in the middle is your selected frame. 4. You need to copy music files to your storage card first to use the Music app to play music. Browsing music in the library 1. Tap on the Music app’s Now playing screen or Now playing list to go to the library. In the library, your music is organized by categories such as Artists and Albums.