Plastic Part Design

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To insure a quality final product, it is necessary to start out with quality components. Injection molded parts can be molded to a high quality
standard by focusing on these areas of plastic technology:
1) Correct Part Design
2) Accurate Selection of Material
3) Processing Plastic Processing
Only by drawing on expertise from these three areas of plastic technology can a product designer create quality molded parts that maximize
performance and are cost effective. The purpose of this design guide deals with the first of these three issues - part design.

Correct Part Design Guidelines

If there was only one rule for the injection molding process it would have to be to maintain uniform wall thickness. Here are some examples
of problems associated with part designs that feature a non-uniform wall thickness.

Sink marks due to uneven shrinkage

Stress due to uneven shrinkage

Sink marks result from a wall yielding to the

Sink marks result from a wall yielding to the

still shrinking interior mass.

still shrinking interior mass.

Voids due to uneven shrinkage

Warping due to uneven shrinkage

The already cooled section will not yield to

Concentrated stress at the junction of high &

the shrinking action of the cooling interior

low shrinkage area may cause a part to warp.

mass causing voids in the thick portion of the

part.

Draft
Plastic parts are always designed with a taper or draft in the direction of mold movement to allow part ejection or removal from the mold.
Since plastics shrink when cooled, it is common for parts to shrink (or grip tightly) to cores. A good definition for draft would be: the degree of
taper of a side wall or rib needed to allow the molded plastic part to be removed from the metal mold. Without proper draft, plastic parts may
be difficult to remove from the mold. A draft angle of 1/2 degrees is regarded as minimum for most applications. Draft angles of 1 1/2 to 2
degrees per side are considered normal for plastic injection molding.

Ribs
Many times the stiffness of a part must increase because of the load applied to the part design. One of the easiest ways to cure this problem
is change the part geometry by adding ribs. The use of ribs is a practical way and economical means of increasing the structural strength of
a part. But there are guidelines that govern adding ribs without causing sink marks or surface blemishes to your parts.

1) Rib thickness should be less than wall

thickness. A rib thickness of 60% to 80% of
nominal wall thickness is recommended.
2) To increase stiffness increase the number
of ribs or 'gusset plates', another feature
designed to strengthen the plastic part.
3) For a given stiffness, it is better to increase
the number of ribs, not the height.
4) For thick ribs 'core out' the rib from the
back. This creates a hollow space underneath
the part and maintains a uniform wall
thickness.

Height: Maximum height of three time nominal wall thickness of part.

Spacing: Minimum of two times nominal wall thickness of part between ribs.

Holes
Holes are easy to produce in molded parts. Core pins that protrude into the mold cavity make the holes when the part is molded. Through
holes in the molded parts are easier to produce than blind holes, which do not go all the way through a part. Blind holes are made by core
pins supported on one end only. The pins can be deflected and pushed off center by the pressures of the molten plastic material during the
molding process. A good rule of thumb: the depth of the blind hole should be about twice the diameter of core pins up to 3/16", and up to four
times the diameter of core pins over 3/16". The guidelines for blind and through holes are seen below.

Blind Hole (shown with draft)

L = 2D for Diameters Less than 3/16" dia. core pins
L = 4D for Diameters More than 3/16" dia. core pins

Through Hole (shown with draft)

L = 4D for Diameters less than 3/16" dia. core pins
L = 6D for Diameters more than 3/16" dia. core pins

There are definite rules for the placement of cored holes in a molded part. If these minimum distances shown below are not followed, the
holes will be egg shaped or the part will deform in the areas around the holes.

T = Wall thickness of part

D = Diameter of hole

As depicted above, the distance from the edge of a hole to a vertical surface (i.e. rib) or the edge of a part should be twice the part thickness
(or more), or at least one diameter of the hole. This same rule applies between holes - at least two part thicknesses or one hole diameter
should be specified.
As easy as it is to make holes in molded parts it does not come without some concerns for the strength of the part. For every cored or
molded hole there will be a weld line. The weld lines are caused by the flow of the melted plastic around the core pins. These weld lines are
not as strong as the surrounding plastic material, and also may detract from the overall appearance of the molded part. The part designer
should consider these points when designing holes in a molded part.

The coring of holes is easy when the axis is parallel to the parting line. But when holes and other features run perpendicular to the parting line
then retractable cores (or cams) are required. Split pins and cores (called passing steel shutoffs) can be used to create some of the features.
The designer needs to be aware of the problems of side action cores and the added expenses associated with these types of molds. With a
little understanding of how the mold opens and where the parting line will exist, these costly features can be modified. Rule of thumb:
whenever possible all design features should be incorporated in the same direction of the mold opening so that cam action can be avoided.

Bosses
Bosses are used for locating, mounting, and assembly purposes. There are boss design guidelines that must be followed to insure the
highest quality in molded parts. Again, one of the main points to consider is nominal wall thickness. Too many times bosses are designed
with thick wall sections that can affect the appearance of the plastic part and the final product.

Rule of thumb: the wall thickness around a boss design feature (t) should be 60% of the nominal part thickness (T) if that thickness is less
than 1/8". If the nominal part thickness is greater than 1/8" the boss wall thickness should be 40% of the nominal wall.

Boss diameter, wall thickness, and height design parameters. While boss heights vary by design, the following guidelines will help avoid
surface imperfections like sink marks and voids: the height of the boss should be no more than 2 1/2 times the diameter of the hole in the
boss.
Please observe the "60/40" rule (see above) for the wall thickness at the bottom of the boss.

Insert Molding Tips

Another problem concerning high stress occurs with molded-in inserts. The plastic melt heats the metal of the inserts. During the cooling
stage of injection molding, the plastic part cools, but the plastic boss surrounding the metal insert is reheated by the heat from the insert.
This allows the plastic to continue to shrink around the insert, causing excessive hoop stress* that will eventually cause the boss to crack.
The better design and process would be to use ultrasonic insertion or a hot probe (such as a heat staking unit) after the molded part has
cooled throughout.

Hoop stress: stress within the circumference of the boss

Replacing Metal with Plastics

There are numerous reasons why replacing metal parts with plastic makes sense. Plastics One, Inc. has worked with many companies on
metal-to-plastic conversions. Here is why plastic may be the best option for your parts.
DECREASE PIECE PART PRICES
A penny saved is a penny earned. After initial tooling costs are paid, the piece part pricing is usually much less than the same part produced in
metal, whether it be a stamping, casting, or a die cast part This cost savings is realized because the injection molding process has faster
cycle times (more parts made per machine hour) and these parts are identical from one to the other which eliminates secondary machining.
ELIMINATE TIME-CONSUMING AND COSTLY SECONDARY OPERATIONS
Eliminating secondary operations further reduces costs. Plastic material can be colored with color concentrates before molding - eliminating
secondary painting operations. Injection molds can be textured or given various levels of polished surfaces before molding. The costly
assembly of several metal stampings or castings fastened together can often be replaced by a single injection molded part incorporating the
features of the total assembly. If multiple assemblies are required, the plastic parts can have snap-together features to eliminate any
fasteners. Eliminating sub-assembly tooling or fixtures by using injection molded parts can quicken delivery in new product development
programs.
REDUCE PRODUCT WEIGHT AND IMPROVE USER EASE
One primary advantage of using plastics instead of metals is weight reduction Reducing product weight with plastics gives you more parts
per pound of material, significantly reduces shipping costs and improves the end-user's physical ease in utilizing the product A comparison of
the specific gravity values of metals to plastics is shown in the following table:

METALS

Aluminum 2.5 to 2.8

PLASTICS

Polycarbonate 1.2 to 1.4

Brass 8.4 to 8.7

Nylon (most types) 1.2 to 1.7

Copper 8.8

Polyethylene .92 to .95

Zinc 6.9 to 7.2

Polypropylene .90 to 1.04

Steels 7.7 to 7.83

ABS 1.02 to 1.4

GAIN GREATER PRODUCT STRUCTURAL STRENGTH

That third little pig really knew how to choose the right materials to build a strong house. Choosing plastic over metal gives you products
which are light-weight, easier to use and yet possess increased structural strength. Plastic parts can be stronger than metal parts through the
use of engineering grade materials. In addition, the ability to mold in structural strength such as ribs, bosses and gussets when the part is
originally produced instead of fastening, welding and gluing operations afterwards can affect the total strength of the assembled part as well
as reduce additional costs.
INCREASE YOUR PRODUCT DESIGN OPTIONS
Don't let the design limitations of metals trap you between a rock and a hard place. Increase your design options and requirements and still
keep costs down. The area of greatest difference between metals and plastics is the ease in producing complex shapes. The costly assembly
of several metal stampings or castings fastened together can often be replaced by a single injection molded part incorporating the features
of the total assembly. If multiple assemblies are required, the plastic parts can have snap-together features to eliminate any fasteners.
Injection molded parts can shorten the time to the market place in new product development programs because of elimination of subassembly tooling or fixtures. If heavy metal shakes, rattles and rolls, then plastic twists and shouts. Plastics are easily processed into
complex shapes that would be impossible for metal because plastic materials have non-Newtonian flow behavior. This means that the
viscosity (resistance to flow) will decrease when the flow rate increases. The flow rate is increased by increasing the injection pressures. The
standard injection molding pressures are 20,000 to 30,000 Psi. This capability allows plastics to be made to flow to produce thin walled parts
with uniform wall dimensions replacing the more costly thicker-walled design features of most metal parts.
SAVE DOLLARS BY RE-USING MATERIALS
Any way you look at it, recycling makes sense. Re-using materials by adding regrind (ground up runners and scrap parts) to virgin materials
generates even more cost savings. Plastic materials fall into two basic types of process groups: Thermoset and Thermoplastic. Thermoset
(often called compression molding) is like working with epoxy. Once the material has been heated and formed in a mold, it is set. The material
cannot again be processed; it is literally a reaction by temperature or thermally set. Examples of thermoset materials are Alkyd, Polyesters,
Melamine and Phenolic. Most injection molding plastics are thermoplastics; that is they can be reprocessed. Thermoplastics fall into two
distinctive molecular groups: amorphous and crystalline. Amorphous materials when processed act like honey; that is they never really melt,
they just soften and are formed under pressure. Crystalline materials act like solder or ice. They have a specific melt temperature and remain
a solid until this temperature is reached. After the melt temperature is achieved, the materials flow very easily with very low viscosities. When
the material is cooled to a temperature below the melt temperature, the material hardens to a solid form.

Amorphous Materials

Crystalline Materials

Acrylic

Nylon

ABS

Polypropylene

Polystyrene

Acteal

PVC

Polyester

Polycarbonate

Polyethylene

Comparison Characteristics:
Shrinkage

.004 - .012/in/in

.012 - .025/in/in

Ease of flow

relatively stiff flowing

easy above melting

Dimensional control of

easier to maintain close dimensional

temperature more difficult to

parts

tolerances

maintain close dimensional control

INCREASE PRODUCT LIFE

The Tin Man needed more than a brain to last - he needed an endless supply of oil as well. Replace the environmental vulnerability of metals
with the durability and longevity of plastics. Most plastic materials have greater chemical resistance than most metals. Plastics do not rust or
oxidize as metals do and most are not affected, as are metals, by acids or base compounds.

Design Guidelines for Metal to Plastic Conversions

There are several common mistakes made when replacing a metal product with a plastic molded part. The new part design must adhere to
specific material and molding process guidelines. Several of the general guidelines are shown below:

See guidelines for uniform wall thickness when coring out sections

See Draft section for design specifications

Since 1949, Plastics One has specialized in the custom design, tooling, and injection insert molding of products used in the medical,
telecommunications, aerospace and consumer products industries. Our Engineering and Tooling divisions are staffed by designers and mold
makers with the knowledge and computer-aided design experience to create the exact part for your needs. As molders, we specialize in
custom injection molding and insert molding using a wide variety of engineering polymers, from thermoplastic elastomers to reinforced or
filled resins. Shot sizes range from 1/10th of a gram up to 80 ounces. In addition, we offer hot stamping, ultrasonic welding, and packaging
services for your convenience.
We invite you to visit our manufacturing plant. You'll see first-hand why our "Success is in the Details."

InjectionMoldingVa is a division of Plastics One

map 6591 Merriman Rd. Roanoke VA 24018
02/29/16 05:29