CHAPTER 3 :

MOULD
(PART 4)
 OBJECTIVE :
3.5 Perform the design of two-plate injection mould
a. Design a plastic part
b. A two-plate mould of the plastic part
c. A detail drawing of the mould
d. The assembly of the mould
e. An explode drawing of the mould

3.6 Describe the sustainable elements

to increases tool life and awareness
of environment

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3.5 Perform the design of two-plate injection mould
a. Design a plastic part

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a. Design a plastic part
Study of Component Drawing:
• This is most important and the first step for the designer.
• The component drawings are carefully scrutinized to extract the
maximum possible amount of information available such as critical
dimensions, line of draw, parting line, suitable ejection system, and
required side core.
Design Example:

Figure 1: View of a Fan blade back cover

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a. Design a plastic part
Component Description:
• The component is a back cover of fan blade unit which plays an
important role in the assembly of the complete equipment.
• The component is designed in such a way that it conceals the
complete assembly and also balances outside with other
adjoining parts or assemblies due to which the cover is designed
in such a way as to ensure both the applications.
• There is a hole in the side surface
of the component to facilitate the
necessary cables for the fan motor
after assembly.
• As per requirement a two cavity
injection moulding tool is to be
developed.
Figure 1: View of a Fan blade back cover
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b. A two-plate mould of the plastic part
• The critical items to be considered while designing are:
 Shrinkage.
 Selection of Parting Surface.
 Number of Cavities.
 Feed System.
 Cooling System.
 Ejection System.
 Venting.
• Selection of the Tooling Material:
 Suitable material is chosen for manufacturing of each part
of the tool depending on their primary function & use.
 The different tooling materials used for each part of the
tool is given in bill of materials.

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b. A two-plate mould of the plastic part
• A two cavity injection molding tool design and its mold flow
analysis for a given component was taken up according to
the industrial specification.
• Polypropylene (PP) is thermoplastic material used for Fan
Blade Back Cover due to its light-weight, durability,
recyclable, rugged and resistant to chemical solvents.
• The present work covers the Design, Analysis and
Manufacturing of two cavity injection mold for fan blade
back cover of polypropelene.
• The design of the tool is aimed for a high productivity and
to obtain good quality of products economically.

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COMMANDMENT #1: UTILIZE CONSTANT WALL THICKNESS

• Constant wall facilitates material flow – no eddying…

• Facilitates cooling – thickest section dictates cooling
time
• 2x wall = 6x to 8x cool time
• Sink – materials shrink according to how thick they are
• AVOID – thin to thick to thin (thick to thin okay, to a
point…)

sink

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COMMANDMENT #2: UTILIZE RIBS AND BOSSES FOR STRUCTUR
• Ribs add local structure
• Height gives 3rd order increase in strength
• Thickness at root should be 50% - 60% of nominal walls
• Look for thin steel conditions (gap <2t)
• Look for places where design is weak locally to reinforce
with ribs
• don’t overdesign/overcompensate!!

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COMMANDMENT #2: UTILIZE RIBS AND BOSSES FOR STRUCTUR

• Bosses add local structure

• Great opportunity for sink if done poorly

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COMMANDMENT #3: AVOID SHARP CORNERS &
TRANSITIONS
• Outside radii should be no smaller than the smallest cutter from the machine shop (ask your
moldbuilder)
• Allows easier flow of material through mold
• Radii reduce stress concentration in molded parts

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COMMANDMENT #3: AVOID SHARP CORNERS &
TRANSITIONS
• What do sharp corners cause on molded parts?
• Flow anomalies (eddying) will certainly occur
• Stress concentrators
• CNC cutters can’t make them in steel – must be (longer / more $)

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 COMMANDMENT #5: AVOID UNDERCUTS / MOLD SIDE ACTION
BEWARE OF SIDE ACTION – BUT IF YOU MUST, MAKE THE PART MULTIFUNCTIONAL
• Slides / hydraulic cylinders / horn pins - must move steel out of the way to clear for
ejection
• Adds cost / complexity / failure modes to the mold
• Will cause premature wear
• Adds cycle time – increased cost at part level!

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 COMMANDMENT #6: USE ADEQUATE DRAFT

USE ADEQUATE DR AFT

• Draft is taper that allows part to eject from
mold
• Varies depending on
• Geometry
• Texture
• material

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COMMANDMENT #9: BEWARE OF KNITS LINES &
POTENTIAL SHORT SHOTS
KNIT LINES / SHORT SHOT
• Knit Lines - The location where melt fronts come together
• A function of gate location(s) and geometry
• Approx. 75% -80% of the strength of the section right next to it
• Cannot eliminate them!!!
• Particularly an issue with translucent / clear parts

• Short Shot – melt cools before full fill can be obtained

• MFA can predict this relatively well
• Weigh part and compare to 3D CAD weight

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COMMANDMENT #10: OPTIMIZE GATE LOCATION / TYPE
TO REDUCE MOLDED IN STRESSES AT GATE
CONSIDER PEG – AND PR OVIDE LOCATIONS IF NECESSARY (PADS)
• Gate locations / type
• Ejector Pin locations
• Parting Line

EJECTOR PINS (YELLOW)

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MOLD FLOW ANALYSIS

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c. A detail drawing of the mould

Figure 6: Cavity Half

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c. A detail drawing of the mould

Figure 7: Core Half

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c. A detail drawing of the mould

Figure 8: Exploded view of Core Half

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d. The assembly of the mould

Figure 9: Tool Assembly

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d. The assembly of the mould

Figure 10: Fixed Half of the Tool Figure 11: Moving Half of the Tool

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e. An explode drawing of the mould

Figure 12: Exploded view of Mould

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3.6 Describe the sustainable elements to increases
tool life and awareness of environment
Overview of Plastics and Sustainability
• In order for a product or material to be truly described as sustainable it must
be environmentally, economically and socially sustainable.
• These aspects have become known as the Three Pillars of Sustainability.
• Plastics make a positive contribution to all three pillars of sustainability.
• Plastics make an immense contribution to the:
 Environmental sustainability through their energy saving potential and intrinsic
recyclability and energy recovery options.
 Economically plastics form an important part of the economy and are a major
export product.
 Socially the plastics industry is a major and inclusive employer with an attention to
training and education.

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3.6 Describe the sustainable elements to increases
tool life and awareness of environment
5 Good Things About Plastic that Help the Environment
1. Reduced Weight, Increased Fuel Economy
- Plastic is also much lighter than traditional materials like metal and glass,
it also helps cars get more miles per gallon of travel.
2. Reduced Packaging
- Because plastics are light and sturdy, product packaging has become more
streamlined.
3. Lower Impact than Paper
- Many trees and a significant amount of water and energy are needed to
produce paper products.
4. Energy Savings
- Plastic windows and other building parts can filter
UV rays in order to keep buildings cool in the summer
5. Strength and Durability
- Plastic is resistant to corrosion, impact, UV rays &
many other environmental factors, it doesn't have
to be replaced as often as other materials.
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3.6 Describe the sustainable elements to increases
tool life and awareness of environment
Negative impact of Plastic
• Plastic items can’t tolerate high temperatures and releases harmful gases (at high temp.) which
cause pollution.
• Plastic is not easily disposable and it will take thousands of years to completely dispose in soil.
• This result in other harmful things like blockage of water (resulting floods), death of animals, birds
because of eating plastic etc. which are serious concerns of several environmental activists.
• Even the process of making plastic by industries releases heavy amounts of carbon dioxide.

The plastic material has its cons that have to look into as well. They include:
 Toxins
 Plastic materials are known to have various chemicals that are harmful to one’s health.
 Some of the components used to lead to make the product contain the harmful chemical.
 It affects the ecosystem as well: This includes air, water, and soil.

 Non-disposable
 Plastics take longer to decompose.
 This affects the animals, plants, and even sea creatures.
 For example, the discovery of whales that have been washed up to show
after being suffocated by the plastic bags.
 Others have swollen the material, which interferes with their digestion.
 This is a death sentence to the mammal.
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3.6 Describe the sustainable elements to increases
tool life and awareness of environment
Ways we can help:
1. Support the Break Free From Plastic Pollution Act
- Which would phase out throwaway plastics, hold the industry
responsible for its waste and pause construction on new plastic-making plants.
2. Practice waste prevention first and choose to reuse whenever possible.
- Waste disposal must be in accordance with all applicable regulations. Preferred options for disposal are:
1. Recycling,
2. Incineration with energy recovery, and
3. Landfill.
- Recycling of sprue and runners is best done directly at the molding machine.
- Mechanical recycling of post-consumer parts is rarely attractive.
- Since resin stability and mechanical properties can be severely affected by
contamination, the separation & cleaning logistics become complicated and expensive.
- Chemical recycling is technically possible, but again it is presently limited by waste collection and
separation.
- The high fuel value of acetal resins makes it very desirable for material that cannot be recycled.
- However, parts or regrind of resins containing Teflon® (such as Delrin® 500AF and 520MP) should not be
incinerated.
3. Address the plastic pollution crisis rapidly through executive action.
- Demand that he take bold action on plastics for our health, climate and wildlife.

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3.6 Describe the sustainable elements to increases
tool life and awareness of environment

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Thank you

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