Product Design

N.Ravindra Reddy,
CIPET – Ahmedabad.
Design:
• Art of giving shape to the ideas.
• Product of creative thinking.
• Complete description of an object &
Prescription for its production.
Product Design:
• Conversion of ideas into reality and aims at
fulfilling human needs.
 Concepts of Design
• Shape - Geometry.
• Proportionate size.
• Good appearance &
• Reveals the function of the product.
 Essential Factors of Product Design
• Need.
• Physical Reliability – Convertible in to material.
• Economic Worthiness – Compared to available.
• Financial Feasibility.
• Optimality – among the available alternatives.
Mechanical Strength, Better quality, Minimum
weight, Minimum cost etc.
 Essential Factors of Product Design
• Morphology – Study of the chronological
structure of projects.
Feasibility Study
Preliminary Design
Detailed Design
Planning for production

Planning for Distribution

Planning for Consumption

Planning for Retirement

 Essential Factors of Product Design

• Reduction of Uncertainty

• Economic Worth of Evidence

• Bases for Decision

• Minimum Commitment
 Design for Plastics
Advantages of Plastics
• Light Weight.
• Toughness – Difficult to destroy.
• Resilience – Large Strains.
• Vibration Damping.
• Resistance to Fatigue.
• Low Coefficient of Friction.
• Thermal Insulation.
• Corrosion Resistance.
• Colour Possibilities.
• Manufacturing Methods.
• Integrated Design.
• Price.
 Limitations of Plastic
• Strength, Surface hardness & Abrasion
resistance.
• Temperature Resistance.
• UV Resistance.
• Flammability.
• Thermal Expansion.
• Orientation - Relative physical position.
 The Plastic material Selection

• Mechanical Properties.

• Thermal Properties – Maximum & Minimum

anticipated temperature.
• Electrical Properties –
Conductive or Insulating qualities.
• Resistance to chemicals.
Methodical Approach in Plastics Product Design
• Define the function of the part with life
requirements.
• Define the shape and size based on space and
capacity.
• Assess loading conditions, Stress and
deformation.
• Define all environmental conditions.
Methodical Approach in Plastics Product Design
• Select several materials to satisfy the above
conditions and other relevant properties.
• Do several trial designs using different
materials and geometries to perform the
required function.
• Define manufacturing process for each design.
 Methodical Approach in Plastics Product Design
• Evaluate the trial designs on a cost effective basis.
• Based on above study select the best choice & do
detailed design of part.
• Select the material and process.
• Make prototype parts to determine the required
functions.
• Redesign if required.
• Retest if required.
• Manufacture.
• Field test.
• Use.
 Designing with Engineering Plastics
• Wall thickness.
• Parting line.
• Ribs, bosses and gussets.
• Radii and fillets.
• Taper.
• Holes.
• Coring.
• Undercuts.
• Threads.
 Designing with Engineering Plastics
• Inserts.
• Gate location & size.
• Location of ejector pins.
• Tolerances.
• Fastening.
• Shrinkage.
• Surface finish.