Index

Note: Page numbers followed by f indicate figures.

A Calcium carbonate (CaCO3), 102

Abrasive wear, 172–173, 431 Calendering, 464
Acrylic glass. See Poly(methyl methacrylate) Cantilever snap-joint, 214–217
(PMMA) Carbon fibers (CF), 102
Acrylonitrile butadiene styrene (ABS), 117 Carbon steel, 297
Additive manufacturing (AM) Cellulosic materials, 115–116
applications, 263 Chemical resistance, 144
benefits, 262 Chemical wear, 175
binder jetting, 254–255 Coextrusion, 463–464
directed energy deposition (DED), 259 Coinjection process, 499–500
material extrusion, 253 Cold runner molds, 294
material jetting, 254 Colorants, 555
powder bed fusion (PBF), 255–259 Colorimetry, 185–188
prototype Color perception, 184
complexity, 282–283 Commodity plastics
cost/budget, 283 poly(vinyl chloride) (PVC), 107–108
purpose, 280–281 polyolefins, 94–104
quality, 281–282 polypropylene, 99–104
required quantity, 282 styrenics, 105–107
sheet lamination, 259–261 Computer-aided design (CAD), 450–452
vs. traditional techniques, 249–263 Computer-aided design and engineering
vat polymerization, 252–253 (CAD/CAE), 2–3, 22
weaknesses, 262–263 Computer-aided engineering (CAE),
Adhesive wear, 173–174, 432 450–452
Aluminum, 299 Computer databases, 90–91
Amorphous polymer, 244–245 Conformal cooling, 403–405
Anisotropic materials COPE. See Thermoplastic copolyesters
flow, 227 (COPE)
subcomponent approach, 233–239 Copper alloys, 300
Anisotropy, 202–205 Cost factors, 134–139
Annular snap-joint, 217–219 Creep, 223–225
Arc spray metal tooling, 390–391 data, 222–223
Cross-linked polyethylenes (XPE), 96–97
B
Back molding
fabric overmolding, 507–509
D
Design for reuse, 73–74
in-mold decoration/in mold labeling, 507 Design from recycling, 42–44
Ball joints, 219–221
Directed energy deposition (DED), 259
Binder jetting, 254–255 Direct laser metal forming (DLMF), 257
Direct laser metal sintering (DLMS), 257
C Direct metal laser sintering (DMLS), 276–279,
CAD. See Computer-aided design (CAD) 403–405
CAE. See Computer-aided engineering (CAE) Double-ejection systems, 338–339

587
588 Index

Ductile-fragile transition internal welds, 575–576

environment, 567–569 molded-in inserts, 577
loading, 561–563 raw material, 577–578
material compounding, 563–565 sharp corners and small radii, 570
molecular weight, 563 small thickness and warping, 572–575
processing, 565–567 Fatigue wear, 174–175
product design, 561 FDM. See Fused deposition modelling (FDM)
FEP. See Fluorinated ethylene propylene (FEP)
E FFF. See Fused filament fabrication (FFF)
Fiber-reinforced materials, 550–553
EBM. See Electron beam melting (EBM)
Ecodesign, 47–50 Fillers, 554
Ejection system Flame retardants, 555
Flammability properties, 191
blade ejector, 329
D-pins, 328 Flow-induced stresses, 534
elements, 325f Fluid absorption, 144–146
guidelines, 331–333 Fluid assisted injection molding, 489–497
Fluorinated ethylene propylene (FEP), 126
pin ejectors, 327
shouldered pins, 327–328 Fluoroplastics, 123–126
sleeve ejectors, 329–330 Functional systems
centering and guiding, 305–308
stripper plate, 330–331
valve headed ejector, 328 feed system, 308
Electrical properties, 189–190 gates, 312–313
Electron beam melting (EBM), 257 impression, 301–304
runners, 309–311
Electrostatic discharge sensitive devices
(ESDS), 284 sprue, 308–309
End of life (EOL), 68 Fused deposition modelling (FDM), 253,
Engineering plastics, 108–121 284–285, 392–395
Fused filament fabrication (FFF), 253, 263–268
Environmental resistance, 144
Environmental stress cracking (ESC), 144
amorphous engineering polymers, G
114–118 Gas-assisted injection molding, 494–495
crystalline engineering polymers, Glass fibers (GF), 102
109–114
Epoxy tooling, 386–389 H
EPS. See Expanded polystyrene (EPS) Hardened steels, 298–299
Erosive wear, 432
Hardness, 175–176
ESDS. See Electrostatic discharge sensitive High-density polyethylene (HDPE), 96–97
devices (ESDS) High-impact polystyrene (HIPS), 106
Expanded polystyrene (EPS), 106–107 High-molecular weight polyethylenes
Extrusion blow molding, 194–195, 464
(HMWPE), 98
Hot runner molds, 295–296
F hot runner mold configurations, 350
Failure of plastic products manifolds, 350–351
processing nozzles, 351–352
back pressure, 579 valve gated hot runner nozzles, 353
contamination, 581–583 Hybrid molds
photochemical degradation, 583–584 computer-aided design (CAD), 450–452
processing temperature, 580–581 computer-aided engineering (CAE),
product design 450–452
excessive thickness, voids, and sink marks, concept, 413–414
571–572 design
feed system, 576 cooling system, 426–429

ejection system, 425–426
impression and shrinkage, 423–425
injection system, 420–422
dimensional accuracy, 445–450
materials, 415–418
tool integrity, 435–444
tribological issues, 429–435
Hybrid products, 285–289
I M
Imide polymers, 128–129
Injection blow molding, 465–466
Injection cycle time
cooling time, 371
injection time, 370
molding ejection time, 371
mold opening and closing, 371
pressurization time, 370–371
total cycle time, 371–373
Injection molding, 192–193
environment impact, 375
molding cycle, 474
mold temperature, 412
pressure, 412–413
process variables, 474–479
reusability, 373–375
Injection molding equipment
clamping unit, 483
control unit, 483
machines, 483–486
plasticization/injection unit, 480–482
power unit, 480
Inorganic fillers, 102
Isotropic materials, 205–213
stiffness, 212–213
strength, 205–212
L Modified polypropylene, 102
Laminated object manufacturing (LOM),
259
LDPE. See Low-density polyethylene
(LDPE)
LFT. See Long fiber thermoplastic (LFT)
Life cycle, 47–50
Life cycle assessment (LCA)
life cycle costing (LCC), 80–82
methodology, 75–77
product life cycle, 74–75
Life cycle costing (LCC)
life cycle assessment (LCA), 80–82
Life cycle impact assessment (LCIA), 76–77
Life cycle inventory analysis (LCI), 76
Index 589
Limiting oxygen index (LOI), 191
Linear low-density polyethylene (LLDPE), 97
LOM. See Laminated object manufacturing
(LOM)
Long fiber thermoplastic (LFT), 130
Long-term tests, 203–205
Low-density polyethylene (LDPE), 98
Machine hour rate, 137–139
Material compatibility, 504–506
Material extrusion, 253
Material jetting, 254
MDPE. See Medium-density polyethylene
(MDPE)
Mechanical design
anisotropic materials
subcomponent approach, 233–239
isotropic materials
stiffness, 212–213
strength, 205–212
processing, morphology and properties,
227–232
Mechanical properties
data for stiffness, 150–151
data for strength, 148–150
glass temperature transition, 152
impact loading, 158–159
long-term behavior, 153–157
plastic composites, 152–153
Medium-density polyethylene (MDPE), 98
Melt-processable rubber (MPR), 121
Melt processing
continuous products, 462–464
processing route, 457
screw extrusion, 460–462
thermoplastics, 457–459
Mold calculations
feed system
gate design, 357–358
runner design, 359
injection pressure
center-gated discs, 364–365
circular cylindrical channels, 364
tapered cylindrical channels, 364
total pressure drop, 365–370
temperature control systems, 360–363
Molding elements, 412
Molding processes
extrusion blow molding, 464
injection blow molding, 465–466
590 Index

Molding processes (Continued) P

rotational molding, 466–471 PA. See Polyamide (PA)
thermoforming, 466 PBF. See Powder bed fusion (PBF)
Molds PC. See Polycarbonate plastics (PC)
functional systems, 301–316 PEEK. See Poly(arylether ketones) (PEEK)
hybrid molds, 118 PET. See Poly(ethylene terephthalate) (PET)
materials, 296–300 Physical properties, 144
rotating movements, 348–349 Plasticizers, 554
side movements Plastic products
compression springs, 346 assembly, 32
guide driving, 342–346 constant-stress beams, 26–32
hydraulic systems, 347 design, 18–20
structure, 300–301 design guidelines, 13–14
temperature control, 487 manufacturing
types, 293–296 drafts, 37
Molecular weight, 165–167 features, 38
MPR. See Melt-processable rubber (MPR) finishing, 34–35
Multicomponent injection molding, 497–506 gating, 36
MultiJet modelling process (MJM), material, 34
395–399 mold shrinkage, 37–38
radius, 35
N ribbing, 36–37
Nonconventional molding techniques, wall thickness, 35
488–509 maximize material efficiency, 25–32
Non-Newtonian fluids, 163–164 minimize costs, 23–24
Nonstandard ejection processes molded-in inserts, 32–33
combined compressed air-assisted ejection, number of components, 25
333–334 simultaneous engineering, 20–22
double-ejection systems, 338–339 specifications
ejection from injection side, 334 detail design, 16–17
forced ejection, 335 material selection, 15–16
parts with undercuts, 334–335 new concepts, 14–15
retractable/expandable cores, 336 tool design, 17
slanted ejectors, 336–338 structural foams, 25–26
spring steel ejectors, 336 sustainability
recycling, 39–41
O Plastics
Optical properties cost factors, 134–139
clarity, 182–183 design and processing, 3
color, 184 high temperatures, 121–129
colorimetry, 185–188 mechanical behavior, 202–205
color perception, 184 product development, 2–3
gloss, 179–180 sustainability, 3–4
haze, 181–182 viscosity, 164–165
refraction and reflection, 177–179 Poly(arylether ketones) (PEEK), 128
transparency, 180–181 Poly(ethylene terephthalate) (PET), 118
visual color assessment, 184 Poly(methyl methacrylate) (PMMA), 116
Orientation, anisotropy Poly(phenylene oxide) (PPO), 118
flow, 227 Poly(phenylene sulfide) (PPS), 127
processing, 530–532 Poly(styrene-co-acrylonitrile), 106
reinforcement, 532–533 Poly(vinyl chloride) (PVC), 107–108
Overmolding injection techniques, 501–504 Poly(vinyl fluoride) (PVF), 126
 Index 591

Poly(vinylidene fluoride) (PVDF), 126 Pseudomolding method. See Subcomponent

Polyacetal or polyoxymethylene or approach
polyformaldehyde (POM), 112–114 PTFE. See Polytetrafluoroethylene (PTFE)
Polyamide (PA), 109–112 PVC. See Poly(vinyl chloride) (PVC)
Polycarbonate (PC), 116–117 PVDF. See Poly(vinylidene fluoride) (PVDF)
Polyethylene, 95–98 PVF. See Poly(vinyl fluoride) (PVF)
Polyimides, 128–129
Poly Jet system, 268–271, 399
Polyolefin blends, 120
Q
Quaternary recycling, 56
Polyolefins, 94–104
Polypropylene (PP), 99–104
copolymers, 101–102 R
homopolymer, 99–101 Rapid prototyping (RP)
living hinges, 103–104 direct process, 392–407
structural foams, 102 draft angles, 409
Polystyrene (PS), 105–106 indirect processes, 385–391
Polysulfones, 127 injection molding processing, 411–413
Polytetrafluoroethylene (PTFE), 123 part details, 411
POM. See Polyacetal or polyoxymethylene or surface finishing, 410
polyformaldehyde (POM) surface quality, 410–411
Powder bed fusion (PBF), 255–259 technologies, 381–384
PPO. See Poly(phenylene oxide) (PPO) Rapid tooling (RT), 384–385
PPS. See Poly(phenylene sulfide) (PPS) Raw material, 134–136
Pretreated steels, 297–298 Reaction injection molding (RIM), 136
Primary recycling, 53–55 Real 3D-printing, 254–255
Processability Recyclability, 67–69
extrusion blow molding, 194–195 Recycling
injection molding, 192–193 algorithms, 57–67
materials and processing, 197 categories and typologies, 52–57
rotational molding, 194 concept, 50–52
screw extrusion, 193 Reference stress, 206–208
structural foam molding, 197 Reinforced thermoplastics, 129–133
thermoforming, 195–197 Residual stresses, 533–536
Process variables Reusing products
cooling time, 478 framework, 69–73
flow rate, 477 packaging, 72
holding pressure, 478 procuring furniture design, 72–73
holding pressure time, 478 Rheological properties
injection molding machines, 477 fluids and flow, 162–165
injection pressure, 477 spiral flow, 167–168
melt temperature, 479 RIM. See Reaction injection molding (RIM)
mold temperature, 479 Rotational molding or rotomolding, 194,
Product design, 7 466–471
Production cells, 486–488 cycle, 468–469
Product life cycle, 74–75 equipment, 469–471
Product specifications, 88–89 RT. See Rapid tooling (RT)
PS. See Polystyrene (PS) Rules for plastic products, 22–33
Pseudoelastic method
application, 223–227 S
creep and stress relaxation, 221 Safety factor, 208–212
stiffness, 222–223 SBS. See Styrene block copolymers (SBS)
time dependent properties, 221–222 Screw extrusion, 193
592 Index

Secondary recycling, 55 Thermoplastic copolyesters (COPE), 121

Selective heat sintering (SHS), 257–258 Thermoplastic elastomers, 119–121
Selective laser melting (SLM), 257, Thermoplastic polyesters, 118
405–407 Thermoplastic polyether block amides
Selective laser sintering (SLS), 257, 271–275, (TPE-A), 121
399–402 Thermoplastic polyurethanes (TPU), 121
Semicrystalline polymer, 243–244 Thermoplastics, 1, 9
SF. See Structural foams (SF) computer databases, 90–91
Sheet lamination, 259–261 cost factors
Short-term tests, 203 machine hour rate, 137–139
Shrinkage processing, 136–137
differential shrinkage, 523–530 raw material, 134–136
material, 516–519 tooling, 136
processing variables, 519–522 design process, 87–89
tolerances, 512–515 general properties, 141–146
SHS. See Selective heat sintering (SHS) mechanical properties, 147–159
Silicone molds, 386 specifications, 89–90
Simultaneous engineering, 20–22 Thermoplastic vulcanizates (TPE-V), 120
SLA. See Stereolithography (SLA) Three-dimensional printing (3DP), 405
SLM. See Selective laser melting (SLM) Three-plate molds, 339–341
SLS. See Selective laser sintering (SLS) TPE-A. See Thermoplastic polyether block
Snap-joints, 213–221 amides (TPE-A)
Specific gravity, 141–143 TPU. See Thermoplastic polyurethanes
Stainless steels, 298 (TPU)
Stereolithography (SLA), 253, 392, 434 Tribological properties
Stress relaxation, 221 friction
Structural foams (SF), 102, 197, 492–493, plastic products, 168–169
556–561 processing, 169–172
Styrene block copolymers (SBS), 120 wear of polymers, 172–175
Styrenics, 105–107
Subcomponent approach
U
application, 243–245 Ultra-high-molecular weight polyethylenes
design methodology, 239–245 (UHMWPE), 98
flexural stiffness, 237–239 Ultrasonic AM (UAM), 259
mechanical testing, 234–237
Ultraviolet (UV) stabilizers, 555–556
Sulfone polymers, 127
Sustainability
design, 38–44 V
life cycle costing (LCC), 77–78 Vat polymerization, 252–253
mold design, 373 Venting system, 316–318
Viscoelasticity, 202–205
Visual color assessment, 184
T
Tangent modulus, 151
Temperature control, 319–325 W
Tertiary recycling, 55–56 Warpage, 536–537
Thermal properties Waste Framework Directive (WFD), 48
conductivity, 160 Water-assisted injection molding, 495–497
linear expansion coefficient, 160–161 Weld lines, 537–543
operating temperatures, 161
Thermoforming, 195–197, 466 X
Thermo-mechanical induced stresses, 534 XPE. See Cross-linked polyethylenes (XPE)