Table of Contents

1. Introduction ........................................................................................................................1
2. Product Description ...........................................................................................................1
2.1. Product ........................................................................................................................1
2.2. Parts of Product ...........................................................................................................2
2.3. Special Requirements ..................................................................................................2
3. Material Properties .............................................................................................................3
4. 3D Model of The Assembly and Parts ...............................................................................4
5. Calculations for Cavity Numbers.......................................................................................5
5.1. Specifications of The Machine ....................................................................................5
5.2. Molding Weight ..........................................................................................................6
5.3. Required Shot Capacity Per Part .................................................................................6
5.4. Plasticizing Capacity of Machine ................................................................................6
5.5. Projected Area for Clamping.......................................................................................6
5.6. Number of Cavities Per Each Criteria .........................................................................7
5.6.1. Cavities Based on Shot Capacity .........................................................................7
5.6.2. Cavities Based on Plasticizing Capacity ..............................................................7
5.6.3. Cavities Based on Clamping Force ......................................................................7
5.6.4. Cavities Based on Demand ..................................................................................8
6. Cavity Layout of The Mould .............................................................................................8
7. Ejector Pins, Cooling Channels, and Runner Design ........................................................9
8. References ........................................................................................................................10

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Table of Figures

Figure 2.1-1 PC Mouse Assembly .............................................................................................1

Figure 2.2-1 Button and Top Palm Holder ................................................................................2
Figure 2.2-2 Bottom Base ..........................................................................................................2
Figure 2.2-3 Transparent Mid ....................................................................................................2
Figure 2.3-1 Assembly ...............................................................................................................4
Figure 2.3-2 Bottom Base ..........................................................................................................4
Figure 2.3-3 Transparent Mid ....................................................................................................4
Figure 5.6-1 Cavity layout of bottom base ................................................................................8
Figure 5.6-1 Mold Base .............................................................................................................9
Figure 5.6-2 Ejectors, Runners, and Cooling Channels .............................................................9

Table of Tables

Table 3-1 Polycarbonate Properties ...........................................................................................3

Table 5-1 Machine Specifications .............................................................................................5

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1. Introduction

Injection molding process used for high quantity production that needs to achieve
consistent geometrical tolerances and mechanical properties. Most of the plastic parts in world
are injection molded. For this process to continue without human interaction an automatic
injection molding machine need. The tool used to get desired part is called injection mould.
Producing this mould tool is very complicated task and need proper experience in molding
industry. Various thermoplastic and thermoset materials can be used in this process such as
ABS, polycarbonate, polypropylene, HIPS, polyethylene, and nylon etc.

2. Product Description

2.1. Product
PC mouse assembly chosen as the plastic part. Figure 2.1-1 shows images of HP wired
mouse assembly.

Figure 2.1-1 PC Mouse Assembly

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 2.2. Parts of Product

Figure shows some of parts in mouse assembly. This assembly originally contains 6
plastic parts 3 parts are black and 3 parts are transparent. 2D drawing of the assembly is
attached in annex.

Figure 2.2-2 Transparent Mid Figure 2.2-1 Bottom Base

Figure 2.2-3 Button and Top Palm Holder

2.3. Special Requirements

This part is made for easy assembling and not for frequent disassembly. Therefore,
several snap locks are included, and undercuts are also included for easy assembly. Undercuts
are omitted due to its complexity.

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3. Material Properties

Polycarbonate used to manufacture these parts due to heat and scratch resistance.
Following table shows properties of material[1].

Table 3-1 Polycarbonate Properties

Property Units ASTM Value

Test
Tensile Strength psi D638 9,500
Tensile Modulus of Elasticity psi D638 345,000
Tensile Elongation % D638 135
Flexural Strength psi D790 13,500
Flexural Modulus of Elasticity psi D790 345,000
Compressive Strength psi D695 12,500
Hardness scale as noted D785, M70, R118,
D2240 Shore D 80
Izod Impact ft-lbs/in D256 12.0 - 16.0
Coefficient of Linear Thermal Expansion in/in/°F x 10- D696 3.8
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Heat Deflection Temperature (66psi / °F D648 280 270
264psi)
Max Continuous Service Temperature In °F - 240
Air
Specific Gravity - D792 1.20
Water Absorption % D570 0.15
(Immersion 24 hours)

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4. 3D Model of The Assembly and Parts

Figure 2.3-1 Assembly Figure 2.3-2 Bottom Base

Figure 2.3-3 Transparent Mid

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5. Calculations for Cavity Numbers
Four different types of calculations were carried out to get optimal cavity quantity. These are
based on shot capacity of the machine that’s going to mold, plasticizing capacity of the
machine, clamping force of the machine and hourly demand for the product.

5.1. Specifications of The Machine

Assumed SP 80 injection molding machine is going to produce parts with this mold.

Table 5-1 Machine Specifications

Machine Parameters Value

Screw diameter 34mm/42mm

Injection pressure 1900/1250 bar
Stroke / swept volume 120/ 185 cm3
Screw stroke 135mm
Max injection weight 108/ 167g
Injection rate 150/ 229 cc/sec
Plasticizing rate 11.1/13.1 g/s
Screw L/D ratio 18/ 14
Screw speed max 220 rpm
Heating capacity 6.8kW
No of heating zone 4
Nozzle holding force 58 kN. Screw
Clamping force 3200kN
Mold opening stroke 450 mm
Min mold height 200 mm
Max. Daylight 650mm
Distance between tie bars (h x v) 330 x 300 mm
Size of mold plate (h x w) 500 x 500 mm
Ejector force 42kN
Ejector stroke 80mm

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 5.2. Molding Weight
Density of polycarbonate is 1.2g/cm3
Bottom base volume =11cm3

Bottom base weight = 11 x 1.2

= 13.2g

Transparent mid volume =10.5cm3

Transparent mid weight = 10.5 x 1.2

=12.6g

Due to molding cavity loss 10%n added into molding weight.

Bottom base weight = 13.2 x 110%

= 14.52g

Transparent mid weight = 12.6 x 110%

=13.86g

5.3. Required Shot Capacity Per Part

Polycarbonate is amorphous. So multiplied by 0.95.
Shot capacity of machine = 120 x 1.2 x 0.95
=136.8g
5.4. Plasticizing Capacity of Machine
𝑄𝑝𝑠
Plasticizing rate of PC = Plasticizing rate of PS ×
𝑄𝑝𝑐

0.32∗200
= (11.1x3600) x 0.3∗300

= 28416g/hr

5.5. Projected Area for Clamping

Projected area for bottom base = 55cm2
Projected area for transparent mid = 45cm2

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 5.6. Number of Cavities Per Each Criteria

5.6.1. Cavities Based on Shot Capacity

Cavities based on shot capacity for bottom base =

𝑊
𝑁𝑆 = 0.85 ×
𝑚

= 0.85 x 136.8/ 14.52

= 8 cavities

Cavities based on shot capacity for transparent mid = 0.85 x 136.8 / 13.86

= 8.4 cavities

5.6.2. Cavities Based on Plasticizing Capacity

Assume cycle time is 25seconds for each part.

Cavities based on plasticizing capacity for bottom base =

(𝑝×0.8×𝑇𝑐 )
Np =
3600×𝑚

=28416 x 0.8 x 25 /(3600 x 14.52)

= 10 cavities
Cavities based on plasticizing capacity for transparent mid = 28416 x 0.8 x 25 / (3600x13.86)

= 11 cavities

5.6.3. Cavities Based on Clamping Force

Cavities Based on Clamping Force for bottom base=

𝐶
Nc = 𝑃𝐶×𝐴𝑚

= 3200x 1000/(1900 x 105 x 0.5x 0.0055)

= 6 cavities
Cavities Based on Clamping Force for transparent mid = 3200x1000/(190 x 105 x 0.5x 0.0045)

= 7.2 cavities

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 5.6.4. Cavities Based on Demand

For one assembly one part needed from each.

Cavities based on demand = 600parts per hr / (3600/25)
= 4 cavities

6. Cavity Layout of The Mould

According to above calculations minimum 4 cavities need to archive required demand.

Figure 5.6-1 Cavity layout of bottom base

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7. Ejector Pins, Cooling Channels, and Runner Design

Figure 5.6-2 Ejectors, Runners, and Cooling Channels

Figure 5.6-1 Mold Base

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8. References

[1] Curbellplastics.com, “Polycarbonate Material Properties | Curbell Plastics.”

https://www.curbellplastics.com/Research-Solutions/Plastic-Material-
Properties/Polycarbonate (accessed Aug. 07, 2022).

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