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A05!01!005 Introduction To Part Design
A05!01!005 Introduction To Part Design
August, 2019
These contents are provided “AS IS” without warranty of any kind, either
expressed or implied, including but not limited to the implied warranties of
merchantability, fitness for a particular purpose of non-infringement. Some
jurisdictions do not allow the exclusion of implied warranties, so the above
exclusion may not apply to you.
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What to learn
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Outline
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Part Design Consideration
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Part Design Guideline
Bad
Better
Recommended
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Part Wall Transition
3t
flow
Smooth/Tapered Transition:
best design
3t
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Thickness Consideration
Minimize wall thickness as possible
> Thinner walls can lead to more cost-effective production
through use of less material and shorter cycle time.
– The part needs to cool down to low temperature after
injection molding to avoid deformation during ejection
> In theory
– Cooling time is proportional to the square of the thickness
– Or radius^1.6 of circular parts
> Thick part
– Prolong cycle time, longer cooling and packing time
– Increase production cost of each part
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Wall Thickness and Part Design
PP (Polypropylene)
3mm
1mm
2mm
PS (Polystyrene)
3mm
1mm
2mm
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Effect of Rheological Properties
PMMA (Polymethylmethacrylate)
3mm
1mm
2mm
3mm
1mm
2mm
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Maximum Flow Length of
Plastic Materials
LDPE 70-76
PP 63-70
HDPE 57-63
PS 51-63
ABS 45
Acrylic 33-38
Nylon 38
Acetal 36
PC,PVC 25
0 20 40 60 80 (cm)
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Maximum Flow Length of
Plastic Materials
increasing increasing
injection pressure melt/mold temperature
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Wall Thickness of a Part
L
for easy - flow plastics: t = 0.6 + 0.5 e.g.,PP,PE,PA
100
L
for fair - flow plastics: t = 0.7 + 0.8 e.g.,POM,PMMA
100
L
for stiff - flow plastics: t = 0.9 +1.2 e.g.,PC,PSU
100
or
14 PP PMMA
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Part Design Example
2 to 3mm
2.5 mm
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Part Design Example
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Wall Thickness and Shrinkage
sink mark
Shrinkage voids
local heavy section: poor Use two short thick ribs: good
Core out the heavy section: better Use a long thin rib: better
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Wall Thickness and Shrinkage
original design
part warpage
sink mark
sink mark sink mark
thin section
thick section
thick section
rib
voids
better design sink mark
stress concentration
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Part Design Example
Packing Analysis /Volume Shrinkage
Green areas are where volume shrinkages are over 3.5% in the end of packing.
Areas with high thickness are kept hot for the poor heat dissipation. Therefore, uneven
shrinkage of products might easily occur.
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Enhanced Structure by Ribs
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Rib Design and Reinforcement
> Rib thickness, height and the draft angle are related.
– Sink mark occurs at the other surface of thick part.
– The end of ribs are not easy to be filled for thin ribs and
large draft angle.
> The recommended maximum thickness of part is 0.75 of
part thickness (Usually 0.5-0.75 W)
– 0.5 W: for a high shrink material
– 0.75 W: for a low shrink material. < 0.75W
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