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April 2006
Design Guides for PlasticsClive Maier, Econology Ltd
 
TANGRAMTECHNOLOGY
 
 This publication is made up of a series of articles published in Plastics and Rubber Weekly as a piece work. Thekind assistance of the author and PRW is acknowledged in the publication of the work.The publication will be updated in a regular basis as new sections of the guide are published by PRW.The design hints in this booklet are given in good faith and represent current good practice. The short nature ofthe hints means that not all information can be included. No responsibility can be taken for any errors orconsequential damages resulting from using these hints.This publication may be freely reproduced except for sale or advertising purposes. It may be hosted on web sitesfor free downloading providing that it is used in it’s entirety and that reference is made to the original publication. © Clive Maier 2004
Typeset by Tangram Technology Ltd.
 
Contents
Preface ...........................................................................................1Introduction ....................................................................................2Injection moulding .........................................................................4
Basics
1. Wall thickness ..........................................................................................52. Corners ......................................................................................................63. Ribs ..........................................................................................................74. Bosses ....................................................................................................105. Design for recycling ....................................................................Planned
Special features
 6. Living hinge ...........................................................................................137. Bearings .................................................................................................158. Gears .......................................................................................................18
Assembly
 9. Press fits .................................................................................................2310. Snap-fits .................................................................................................2411. Hot air staking ........................................................................................2812. Ultrasonic welding ..................................................................................3013. Hot plate welding ....................................................................................3514. Spin welding ...........................................................................................3615. Friction welding ......................................................................................3716. Induction welding ...................................................................................3817. Laser welding ..........................................................................................3918. Adhesive and solvent bonding ..............................................................40
Special techniques
19. Design for outsert moulding .......................................................Planned20. Design for gas assist injection moulding ..................................Planned
Extrusion ..........................................................................................
21. Design for profile extrusion ........................................................Planned
 Blow moulding .................................................................................
22. Design for extrusion blow moulding ..........................................Planned
Thermoforming ................................................................................
23. Design for thermoforming ...........................................................Planned
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