Product detailing

What is design?
“Everyone designs who devises courses of action
aimed at changing existing situations into preferred
ones”.
Herbert A. Simon
“…. Conception and planning of the artificial.”
Richard Buchanan

“Design … participates in the making of a new culture,

from spoon to city.”
Max Bill
 *Engineers develop
preliminary concepts for
architecture
* Industrial designers
develop renderings to show
styling and layout
Need identification alternatives

Establish target
specifications

Hard Constraints

Product

Soft
Product detailing
• Surface details
• Functional details
• Structural details
• Construction details
• Aesthetics details
• Manufacturability details
• Ergonomics details
 Product detailing tools
• Depends on company’s aims and objectives (e.g. environment)

• Detailing for longevity

• Detailing for energy efficiency
• Detailing for recyclability
• Detailing for recycled content
• Detailing for bio-degradability or compost ability
• Detailing for transport efficiency
Detailing of plastic products
• Successful product development requires a coherent teamwork
between industrial designers and other specialists- tool designer and
manufacturing operators
Causes of failure
(Smithers Rapra, 2014)

Poor specifictaion and

material selection
15%
Design

20% 45%
Processing

20% Misuse
BIS system of designation of • Steel: tensile strength,
engineering materials carbon content,
composition of alloying
elements

• Fe 360: steel with minimum tensile strength

of 350N/mm2

• FeE 250 : steel with minimum yield strength

of 250 N/mm2

Stress strain curve

 • 55C4
Plain carbon steel with 0.55% carbon and 0.4% manganese

• A figure indicating 100 times the average percentage of carbon

• A letter C
• A figure indicating 10 times the average percentage of manganese

Factor of safety
f = failure stress/ working load
Injection molding
• Two halves of the mold must be
closed tightly
• Vents are cuts within the mold steel
that allows air to escape

• Clamping
• Injection
• Cooling
• Ejection

• Heating
• Forming
• Cooling

• Ejector pins are actuated hydraulically

 • The amount of material that is injected into the mold – shot volume
• Time required depends on shot volume, injection power and pressure

Materials that can be used:

• Acetal
• Acrylic, Acrylonitrile Butadiene styrene
• Cellulose
• Polypropylene
• Polyvinyl chloride
• Elastomers
Advantages: Disadvantages:
• High production rate • Tooling cost higher
• Close tolerance on small intricate parts • High set up cost
• Minimum wastage of material • Large undercut can not be produced
• Complex geometry
• Most Commonly used for processing plastic product
• To process thin walled plastic parts for a wide variety of
shape and size
• E.g. Plastic buckets, syringes
• Before tools are fabricated, the embodiment of a design should be determined
• During the tool fabrication, it is difficult as well as expensive to further change
the design
• For plastic products- load, time or ambient temperature
• Mold size
• Gating way
• Parting line
• Ejection way
• Cavities layout
• Mechanical design
• Accessories
Product detailing
Plastic production process
Additives
Fillers, plasticizers, stabilizers, colorants, lubricants,
flame retardants etc.

Heat, pressure
Monomers Polymers
Catalyst

Polymerization,
condensation or
addition
 Plastics

Thermoplastics Thermosets
Thermoplastics
A material that cures reversibly and softens when heated above the glass transition temperature or melting
point and becomes hard after cooling is called thermoplastic

Thermoplastics have a linear or branched molecular structure

Properties
• High strength and toughness
• Better hardness
• Chemical resistance
• Durability
• Self lubrication, transparency and waterproofing
Examples: Applications
Polycarbonate. ... • Dashboards and car trims
• Toys
Acrylic. ... • Phones
Polyamide. ... • Handles
Polystyrene. ... • Electrical prodcuts
Polypropylene (PP) ... • Bearings
Acrylonitrile Butadiene Styrene (ABS) ... • Gears
• Ropes
Polyester • Hinges and catches
Vinyl • Glass frames
Acetals • Cables
Fluorocarbons • Windows
Thermosets
The material which cures irreversibly and become permanently hard and rigid
after curing are called thermosets

Three dimensional network of covalent

intermolecular bonds (cross-linked)
Types of Thermosets materials Applications
• Alkyds • Electrical equipment
• Allylies • Motor brush holders
• Printed circuit boards
• Amine • Circuit breakers
• Bakelite • Kitchen utensils
• Epoxies • Handles and knobs
• Phenolic • Spectacle lenses
• Polyster
• Silicone
• Polyurethane
• Vinyl Ester
 Structure of Plastics

Linear Branched Cross-linked Network

Isomeric states

Stereoisomers Geometrical Isomers

Cis Trans
Linear structure

Monomer units are linked together to form linear chain-

E.g. nylon, high density polyethylene, polyvinyl chloride, and

polyester
Branched structure
Monomer units are joined to form long chains with
branches of different lengths-

E.g. low density polyethylene, glycogen, and starch

Cross-linked structure

Monomer units are cross-linked together to form cross-linked chains.

chains are connected by covalent bonds-rubber, Bakelite
Network structure

Monomers are joined together to a large three dimensional network.

E.g.: epoxy, phenol formaldehyde
Isomeric states

• Isomers are molecules that have the same molecular formula but
different arrangement of the atoms in space
• Two forms- Stereoisomers & geometrical isomers
• Geometrical isomers- trans and cis isomers depending up on items
in space
Impression
• Free space, the shape of the mould
Gate: top or bottom
 Cavity
• It is the female portion of the
mould which creates the
external plastic part surface

• Cavity insert

Core:
• It is the male portion of the
mould which creates the internal
shape of the plastic component

• Core insert
Flow of material • Narrow space and viscous fluid
• Temperature difference

• Flow of Plastic in Mold Hot plastic is a viscous fluid termed as

‘Melt’ and ease of flow of melt is measured by Melt Flow Index
(MFI).
• The melt is forced to flow inside the mold cavity under high
pressure. Plastic at the center will flow faster than plastic near
the wall because flow speed of the plastic gets reduced due to
the friction with wall and due to solidification of plastic near the
wall.
Wall thickness (t)
More thickness ~ more time

Minimum cooling time

t = Wall thickness
Tm = Melting temperature
Tw = Mold wall temperature
Te = Ejection temperature
α = Thermal diffusivity (the rate of transfer)
 Turbulence (air entrapment)

Maximum force
• Avoid designs with thin areas surrounded by thick perimeter sections as they are
prone to gas entrapment problem

• Maintain uniform nominal wall thickness

• Avoid wall thickness variations that result in filling from thin to thick sections
Use Draft
• Core or redesign thick areas to create a more uniform wall thickness
• Make the outside radius one wall thickness larger than the inside radius to
maintain constant wall thickness through corners
• Round or taper thickness transitions to minimize read-through and possible blush
or gloss differences. Blending also reduces the molded –in stress and stress
concentration associated with abrupt changes in thickness
• Thick ribs often cause sink
• Thin ribs can be difficult to flow
• Rib thickness also determines the cooling rate and degree of shrinkage in ribs, which in turn
affects overall part warpage
• Requires at least 0ne-half degree of draft per side
• Rib height- approximately three times the rib base thickness
• Maintain enough space between ribs for adequate mold cooling
Feed system
• Sprue
• Runner
• Gate
• The runner is a channel machined into the mould plate to
connect the sprue with the entrance (gate) to impression

• The wall of the runner channel must be smooth to prevent

any restriction to flow
Points to consider
• The shape of the cross section of the runner
• The size of the runner
• The runner layout

Four forms of cross-sectional shape

• Fully round
• Trapezoidal
• Modified trapezoidal
• hexagonal
Runner should provide –
• Maximum cross-sectional area from the standpoint
pressure transfer
• Minimum contact on the periphery from the standpoint of
heat transfer
The ratio of cross-sectional area to periphery will give
indication of the efficiency of the runner design
• Round and square types of runner are the two most
satisfactory designs

• The area- periphery ratios exhibited by the semicircular

and rectangular types make their use generally
undesirable
• Square runner is not very satisfactory – it is difficult to
eject
• An angle of 10 degree is incorporated on the runner wall,
thus modifying the square to the trapezoidal section
• The volume of the trapezoidal runner is approximately
25% greater than that of a round runner with
corresponding dimensions (W=D)
• To reduce this differences and still maintain corresponding
dimensions, a modified trapezoidal shape is developed in
which the volume is only 14% greater (approximately)
than its round counterpart
• The hexagonal runner is basically a double trapezoidal
runner, where the two halves of the trapezium meet at the
parting surface.
• The cross sectional area of this runner type is about 82% of
that of the corresponding round runner. Hence, if similar
cross section areas are required, then the value for D must
be increased accordingly.
• Some toolmakers feel that it is easier to match the two
halves of the hexagonal runner compared with matching
the two halves of a round runner.
• This point applies particularly to runners which are less
than 3 mm in width
• Ideally gate should be positioned in line with the center of
the runner to receive material from the central flow
• The basic trapezoidal designs are not as satisfactory in this
respect since the gate can not normally be positioned in
line with the central flow stream
• Fully round runner is formed from two semicircular
channels machined one in each of the mould plates
❖ These channels need to accurately matched to prevent
an undesirable and inefficient runner system
❖ As a result mould cost is higher

Mould cost for a mould containing round and hexagonal

runner will be greater than for one containing trapezoidal
runners
• The choice of the runner is also influenced by the question
whether positive ejection of the runner system is possible
• Consider the case of a two plate mould in which a
circular runner has been machined from both
parting surfaces.
• As the mould opens, the runner is pulled from its
channels in one mould half and it is then ejected
from the other mould half either directly, by ejector
pins, or by relying on its attachments to the
mouldings by the gates
• For multi-plate mould, positive ejection of the runner
system us not practicable.
• Here the basic trapezoidal- type runner is always specified,
the runner channel being machined into the injection half
from which it is pulled as the mould opens. In this way the
runner is free to fall under gravity between mould plates.

• If a circular runner is specified, the runner system could

well adhere to its channel and make its removal difficult
• Summary
• For simple two-plate moulds which have a flat parting surface the fully
round runner or hexagonal runner is to be preferred, the increased
mould cost being relatively small.

• For moulds which have complex parting surfaces, where it would be

difficult to match accurately the semicircular channels of the round
runner or, for multi-plate moulds, the trapezoidal or modified
trapezoidal section should be used.
• Runner size
➢ It depends on following factors-
i) the wall section and volume of the moulding
ii) the distance of the impression from the main runner or sprue
iii) the range of the mouldmaker’s cutters available
iv) the plastic material to be used

• The cross sectional area of the runner must be sufficient to permit

the melt to pass through and fill the impression before the runner
freezes and for packing pressure to be applied for shrinkage
compensation if required. Hence, runner bellow 2 mm diameter are
seldom used and even this diameter is normally limited to branch
runners under 25mm in length
• The further the plastic melt has to travel along the runner the
greater is the resistance to flow. Hence the distance the impression
is from the sprue has a direct bearing on the choice of the cross
sectional size of the runner.
A 5 mm diameter runner may be suitable for a component
weighing 60 g situated 25 mm from the sprue, the same moulding 100
mm from the sprue would require a 7 mm diameter runner.
• The larger the cross-sectional area the greater is the bulk of material
it contains and the longer the period it takes to cool sufficiently to
enable the mould to be opened and the mouldings and runner
ejected.
Hence, it is undesirable to make the runner larger than 10 mm
diameter for most material. However, the rigid PVCs and acrylics are
exceptions due to their high viscosity and diameters up to 13 mm are
used
Feed system
• Sprue
• Runner
• Gate
• The runner is a channel machined into the mould plate to
connect the sprue with the entrance (gate) to impression

• The wall of the runner channel must be smooth to prevent

any restriction to flow
Points to consider
• The shape of the cross section of the runner
• The size of the runner
• The runner layout

Four forms of cross-sectional shape

• Fully round
• Trapezoidal
• Modified trapezoidal
• hexagonal
Runner should provide –
• Maximum cross-sectional area from the standpoint
pressure transfer
• Minimum contact on the periphery from the standpoint of
heat transfer
The ratio of cross-sectional area to periphery will give
indication of the efficiency of the runner design
• Round and square types of runner are the two most
satisfactory designs

• The area- periphery ratios exhibited by the semicircular

and rectangular types make their use generally
undesirable
Area/ periphery ratio
• Square runner is not very satisfactory – it is difficult to
eject
• An angle of 10 degree is incorporated on the runner wall,
thus modifying the square to the trapezoidal section
• The volume of the trapezoidal runner is approximately
25% greater than that of a round runner with
corresponding dimensions (W=D)
• To reduce this differences and still maintain corresponding
dimensions, a modified trapezoidal shape is developed in
which the volume is only 14% greater (approximately)
than its round counterpart
• The hexagonal runner is basically a double trapezoidal
runner, where the two halves of the trapezium meet at the
parting surface.
• The cross sectional area of this runner type is about 82% of
that of the corresponding round runner. Hence, if similar
cross section areas are required, then the value for D must
be increased accordingly.
• Some toolmakers feel that it is easier to match the two
halves of the hexagonal runner compared with matching
the two halves of a round runner.
• This point applies particularly to runners which are less
than 3 mm in width
 • Ideally gate should be positioned in line with the center of
the runner to receive material from the central flow

• The basic trapezoidal

designs are not as
satisfactory in this respect
since the gate can not
normally be positioned in
line with the central flow
stream
• Fully round runner is formed from two semicircular
channels machined one in each of the mould plates
❖ These channels need to accurately matched to prevent
an undesirable and inefficient runner system
❖ As a result mould cost is higher

Mould cost for a mould containing round and hexagonal

runner will be greater than for one containing trapezoidal
runners
• The choice of the runner is also influenced by the question
whether positive ejection of the runner system is possible

• Consider the case of a two plate mould in which a circular

runner has been machined from both parting surfaces.

• As the mould opens, the runner is pulled from its channels in

one mould half and it is then ejected from the other mould half
either directly, by ejector pins, or by relying on its attachments
to the mouldings by the gates
• For multi-plate mould, positive ejection of the runner
system is not practicable.
• Here, basic trapezoidal- type runner is always specified, the
runner channel being machined into the injection half from
which it is pulled as the mould opens. In this way the
runner is free to fall under gravity between mould plates.

• If a circular runner is specified, the runner system could

well adhere to its channel and make its removal difficult
Runner may adhere to its channel, and thereby preventing extraction of the
moulded shot
• Summary
• For simple two-plate moulds which have a flat parting surface the
fully round runner or hexagonal runner is to be preferred, the
increased mould cost being relatively small.

• For moulds which have complex parting surfaces, where it would be

difficult to match accurately the semicircular channels of the round
runner or, for multi-plate moulds, the trapezoidal or modified
trapezoidal section should be used.
• Runner size
➢ It depends on following factors-
i) the wall section and volume of the moulding
ii) the distance of the impression from the main runner or sprue
iii) the range of the mouldmaker’s cutters available
iv) the plastic material to be used

• The cross sectional area of the runner must be sufficient to permit

the melt to pass through and fill the impression before the runner
freezes and for packing pressure to be applied for shrinkage
compensation if required. Hence, runner bellow 2 mm diameter are
seldom used and even this diameter is normally limited to branch
runners under 25mm in length
• The further the plastic melt has to travel along the runner the
greater is the resistance to flow. Hence the distance the impression
is from the sprue has a direct bearing on the choice of the cross
sectional size of the runner.
A 5 mm diameter runner may be suitable for a component
weighing 60 g situated 25 mm from the sprue, the same moulding 100
mm from the sprue would require a 7 mm diameter runner.
• The larger the cross-sectional area the greater is the bulk of material
it contains and the longer the period it takes to cool sufficiently to
enable the mould to be opened and the mouldings and runner
ejected.
Hence, it is undesirable to make the runner larger than 10 mm
diameter for most material. However, the rigid PVCs and acrylics are
exceptions due to their high viscosity and diameters up to 13 mm are
used
 Runner layout
• Number of impressions
• Shape of the components
• Type of mould
• Type of gate

• Runner length should always be kept to a minimum to

reduce pressure losses, and the runner should be balanced
• Runner balancing means that the distance the plastic
material travels from the sprue to the gate should be same
for each moulding.

• It ensures that all the impressions will fill uniformly and

without interruptions providing the gate lands and gate
areas are identical.
Gate
• The gate is a channel or orifice connecting the runner with
the impression. It is a small cross-sectional area when
compared with the rest of the feed system

• The gate freezes soon after the impression is filled so that

the injection plunger can be withdrawn without the
probability of void being created in the moulding by suck-
back
• It allows for simple degating and in some moulds this
degating can be automatic
• After degating a small witness mark remains
• Better control of the filling of multi-impressions can be
achieved
• Packing the impressions with material in excess of that
required to compensate for shrinkage is minimized
• Gate size depends on
i) The flow characteristics of the material
ii) The wall section of the moulding
iii) The volume of material to be injected into the impression
iv) The temperature of the melt
v) The temperature of the mould

• There is no theoretical size for gate (~0.75 – 4mm)

Position of gate