A05!01!005 Introduction To Part Design

A05-01-005
Introduction to Part Design
August, 2019
CoreTech System Co., Ltd. www.moldex3d.com

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2
What to learn
> Learning objectives
– Basic part design guild
> Moldex3D version

– All Moldex3D product
> Recommended user

– All Moldex3D user
3
Outline
> Part Design

– Part Design Consideration
– Part Design Guideline
> Wall Thickness

– Wall Thickness and Part Design
– Thickness Effect
– Wall Thickness and Shrinkage
> Enhanced Structure by Ribs
4
Part Design Consideration
> Product design

– Functionality
– Dimension
– Assemble tolerance
– Appearance
– Cost
– Environmental impact
– Handling
– Others
> It has to integrate with material selection, mold design,

and process conditions
5
Part Design Guideline
> Design the primary wall: from injection molding system of

view.
> Maintain a uniform wall thickness as possible
– From region to region, a different thickness will tend to
shrink differently.
– Variations in wall thickness will affect filling and packing.
– If variations in wall thickness cannot be avoided, try to keep
the variation to a minimum.
Bad
Better
Recommended
6
Part Wall Transition
flow Sharp/Stepped Transition:

t poor design
flow Gradual Transition:

better design
thick-to-thin gating
3t
flow Gradual Transition:

thin-to-thick gating
(not recommended)
3t
flow
Smooth/Tapered Transition:
best design
3t
7
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
8
Wall Thickness and Part Design
> Flow Length/Wall Thickness Ratio (L/t Ratio)

– a measure of moldability of the part
 Maximum Flow Length 

L  
L/t Ratio   
From Gate to Rim
(Average Wall Thickness )
t
Very-difficult-to-
Most parts mold part
relatively easy to mold needs special
equipment
0 100 200 300
L/t Ratio
Heavy-walled parts Thin-walled part difficult to mold,
easy to mold needs special considerations
9
Effect of Rheological Properties
PP (Polypropylene)
3mm
1mm
2mm
PS (Polystyrene)
3mm
1mm
2mm
10
Effect of Rheological Properties
PMMA (Polymethylmethacrylate)
3mm
1mm
2mm
Newtonian (ex. water)
3mm
1mm
2mm
11
Maximum Flow Length of
Plastic Materials
Maximum Flow Length in a 2.54mm(0.1in.) thick part
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)
12
Maximum Flow Length of
Plastic Materials
@constant injection speed, @constant injection

Maximum Flow Length
Maximum Flow Length

mold/melt temperature pressure,injection speed
increasing increasing
injection pressure melt/mold temperature
Part Thickness Part Thickness
13
Wall Thickness of a Part
> Empirical Equation

– t,L in mm
 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 
> Simulation using Moldex3D

– After making the design plan, you can use Moldex3D to
verify the concept quickly.
or
14 PP PMMA
Part Design Example
Runner type: cold runner
Gate size : 1*0.8 mm
2 to 3mm
2.5 mm
15
Part Design Example
Fill: 35% Fill: 50% Fill: 75%
Fill: 85% Fill: 95% Fill: 99%
16
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
17
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
18
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.
19
Enhanced Structure by Ribs

Rib Design and Reinforcement
> Main consideration of Part Structure Design: Part

structure strength is able to resist long-term loading.
> The disadvantages of strengthening structure only by

increasing thickness.
– Part weight and cost increases relatively.
– Lengthen the required cooling time.
– Raise the occurrence of sink mark and voids.
> Adding Rib is the effective methods to reach the required

stiffness and strength and to avoid thick cross sections.
– The well-designed ribs can provide the required structure
strength by only increasing a little weight.
21
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
> The maximum height for rib is 2.5 W.

< 2.5W
22

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A05-01-005

Introduction to Part Design

CoreTech System Co., Ltd. www.moldex3d.com

The following content is provided for educational purposes by CoreTech

Copyright for the following material is primarily held by the CoreTech

> Learning objectives

– Basic part design guild

> Moldex3D version

> Recommended user

> Part Design

> Wall Thickness

> Enhanced Structure by Ribs

> Product design

> It has to integrate with material selection, mold design,

> Design the primary wall: from injection molding system of

flow Sharp/Stepped Transition:

flow Gradual Transition:

flow Gradual Transition:

> Flow Length/Wall Thickness Ratio (L/t Ratio)

 Maximum Flow Length 

Newtonian (ex. water)

Maximum Flow Length in a 2.54mm(0.1in.) thick part

@constant injection speed, @constant injection

Maximum Flow Length

Part Thickness Part Thickness

> Empirical Equation

> Simulation using Moldex3D

Runner type: cold runner

Gate size : 1*0.8 mm

Fill: 35% Fill: 50% Fill: 75%

Fill: 85% Fill: 95% Fill: 99%

CoreTech System Co., Ltd. www.moldex3d.com

> Main consideration of Part Structure Design: Part

> The disadvantages of strengthening structure only by

– Lengthen the required cooling time.

– Raise the occurrence of sink mark and voids.

> Adding Rib is the effective methods to reach the required

> The maximum height for rib is 2.5 W.

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