Basics of Injection Molding Design

Designing plastic parts is a complex task involving many factors that address a list of requirements of the application. How is the part to be used? How does it fit to other parts in the assembly? hat loads will it experience in use? !n addition to functional and structural issues" processing issues play a large role in the design of an in#ection molded plastic part. How the molten plastic enters" fills" and cools within the cavity to form the part largely drives what form the features in that part must take. $dhering to some basic rules of in#ection molded part design will result in a part that" in addition to being easier to manufacture and assemble" will typically be much stronger in service. Dividing a part into basic groups will help you to build your part in a logical manner while minimi%ing molding problems. $s a part is developed" always keep in mind how the part is molded and what you can do to minimi%e stress.

Table of Contents &a' Applications &b' Polymers Best Suited for Injection Molding &c' Injection Molding Equipment &d' Injection Molding Process &e' Injection Molding Cycle &f' Different Types of Injection Molding Processes &g' Stress &h' ates &i' Common ates &#' ate !ocation &k' "all T#ic$ness &l' Draft &m' Sin$ Mar$s &n' Te%tures &o' Parting !ines &p' Common Molding Defects

Applications (lastic in#ection molding is the preferred process for manufacturing plastic parts. !n#ection molding is used to create many things such as electronic housings" containers" bottle caps" automotive interiors" combs" and most other plastic products available today. !t is ideal for producing high volumes of plastic parts due to the fact that several parts can be produced in each cycle by using multi)cavity in#ection molds. *ome advantages of in#ection molding are high tolerance precision" repeatability" large material selection" low labor cost" minimal scrap losses" and little need to finish parts after molding. *ome disadvantages of this process are expensive upfront tooling investment and process limitations.

Polymers Best Suited for Injection Molding +ost polymers may be used" including all thermoplastics" some thermosets" and some elastomers. ,here are tens of thousands of different materials available for in#ection molding. ,he available materials mixed with alloys or blends of previously developed materials means that product designers can choose from a vast selection of materials to find the one that has exactly the right properties. +aterials are chosen based on the strength and function required for the final part- but also each material has different parameters for molding that must be considered. .ommon polymers like /poxy and phenolic are examples of thermosetting plastics while nylon" polyethylene" and polystyrene are thermoplastic.

Injection Molding Equipment

Injection Molding Mac#ine&

!n#ection molding machines" also known as presses" consist of a material hopper" an in#ection ram or screw)type plunger" and a heating unit. +olds are clamped to the platen of the molding machine" where plastic is in#ected into the mold through the sprue orifice. (resses are rated by tonnage" which is the calculation of the amount of clamping force that the machine can exert. ,his force keeps the mold closed during the in#ection molding process. ,onnage can vary from less than 0 tons to 1"222 tons" although the higher tonnage presses are rarely used. ,he total clamp force needed is determined by the pro#ected area of the custom part being molded. ,his pro#ected area is multiplied by a clamp force of from 3 to 4 tons for each square inch of the pro#ected areas. $s a rule of thumb" 5 or 0 tons6in can be used for most products. !f the plastic material is very stiff" it will require more in#ection pressure to fill the mold" thus more clamp tonnage is needed to hold the mold closed. ,he required force can also be determined by the material used and the si%e of the part with larger plastic parts requiring higher clamping force. ,he mold or die refers to the tooling used to produce plastic parts in molding. ,raditionally in#ection molds have been expensive to manufacture and were only used in high)volume production applications where thousands of parts were produced. +olds are typically constructed from hardened steel" pre)hardened steel" aluminum" and6or beryllium)copper alloy. ,he choice of material to build a mold from is primarily one of economics. *teel molds generally cost more to construct but offer a longer lifespan that will offset the higher initial cost over a higher number of parts made before wearing out. (re)hardened steel molds are less wear resistant and are primarilly used for lower volume requirements or larger components. ,he hardness of the pre)hardened steel measures typically 74)50 on the 8ockwell). scale. Hardened steel molds are heat treated after machining" making them superior in terms of wear resistance and lifespan. ,ypical hardness ranges between 02 and 12 8ockwell). &H8.'. $luminum molds cost substantially less than steel molds" and when higher grade aluminum such as 9.): and 9.);2 aircraft aluminum is used and machined with modern computeri%ed equipment" they can be economical for molding hundreds of thousands of parts. $luminum molds also offer quick turnaround and faster cycles because of better heat dissipation. ,hey can also be coated for wear resistance to fiberglass reinforced materials. <eryllium copper is used in areas of the mold which require fast heat removal or areas that see the most shear heat generated.

Mold&

Injection Molding Process ith in#ection molding" granular plastic is fed by gravity from a hopper into a heated barrel. $s the granules are slowly pushed forward by a screw)type plunger" the plastic is forced into a heated chamber called the barrel where it is melted. $s the plunger advances" the melted plastic is forced through a no%%le that seats against the mold sprue bushing" allowing it to enter the mold cavity through a gate and runner system. ,he mold remains at a set temperature so the plastic can solidify almost as soon as the mold is filled.

Injection Molding Cycle &= <ack to ,op' ,he sequence of events during the in#ection molding of a plastic part is called the in#ection molding cycle. ,he cycle begins when the mold closes" followed by the in#ection of the polymer into the mold cavity. >nce the cavity is filled" a holding pressure is maintained to compensate for material shrinkage. !n the next step" the screw turns" feeding the next shot to the front screw. ,his causes the screw to retract as the next shot is prepared. >nce the part is sufficiently cool" the mold opens and the part is e#ected.

Different Types of Injection Molding Processes &= <ack to ,op' $lthough most in#ection molding processes are covered by the conventional process description above" there are several important molding variations including?

.o)in#ection&sandwich'molding @usible&lost" soluble'core in#ection molding Aas)assisted in#ection molding !n)mold decoration and in mold lamination !n#ection)compression molding !n#ection molding of liquid silicone rubber !nsert and outsert molding

Bamellar &microlayer' in#ection molding Bow)pressure in#ection molding +icroin#ection molding +icrocellular molding +ulticomponent in#ection molding&overmolding' +ultiple live)feed in#ection molding (owder in#ection molding (ush)(ull in#ection molding 8eaction in#ection molding 8esin transfer molding 8heomolding *tructural foam in#ection molding *tructural reaction in#ection molding ,hin)wall molding Cibration gas in#ection molding ater assisted in#ection molding

8ubber in#ection

Stress &= <ack to ,op' ,he main enemy of any in#ection molded plastic part is stress. hen a plastic resin &which contains long strains of molecules' is melted in preparation for molding" the molecular bonds are temporarily broken due to the heat and shear force of the extruder" allowing the molecules to flow into the mold. Dsing pressure" the resin is forced into the mold filling in every feature" crack and crevice of the mold. $s the molecules are pushed through each feature" they are forced to bend" turn and distort to form the shape of the part. ,urning hard or sharp corners exerts more stress on the molecule than taking gentle turns with generous radii. $brupt transitions from one feature to another are also difficult for the molecules to fill and form to. $s the material cools and the molecular bonds re)link the resin into its rigid form" these stresses are in effect locked into the part. (art stresses can cause warpage" sink marks" cracking" premature failure and other problems. hile some stresses in an in#ection molded part are to be expected" you should design your parts with as much consideration for stress reduction as possible. *ome ways to do this are by adding smooth transitions between features and using rounds and fillets in possible high stress areas.

ates

&= <ack to ,op'

/ach in#ection mold design must have a gate" or an opening that allows the molten plastic to be in#ected into the cavity of the mold. Aate type" design and location can have effects on the part such as part packing" gate removal or vestige"

ate Types ,here are two types of gates available for in#ection molding- manually trimmed and automatically trimmed gates. Manually Trimmed ,hese type of gates require an operator to separate the aprts from the runners manually after each cycle. +anually ates& trimmed gates are chosen for several reasons?

,he gate is too bulky to be automatically sheared by the machine *hear)sensitive materials such as (C. cannot be exposed to high shear rates

@low distribution for certain designs that require simultaneous flow distribution across a wide front

Automatically Trimmed ates

,hese type of gates incorporate features in the tool to break or shear the gates when the tool opens to e#ect the part. $utomatically trimmed gates are used for several reasons?

$voiding gate removal as a secondary operation" reducing cost +aintaining consistent cycle times for all parts +inimi%ing gate scars on parts

Common ate Designs &= <ack to ,op' ,he largest factor to consider when choosing the proper gate type for your application is the gate design. ,here are many different gate designs available based on the si%e and shape of your part. <elow are four of the most popular gate designs used by 9uickparts customers? ,he Edge ate is the most common gate design. $s the name indicates" this gate is located on the edge of the part and is best suited for flat parts. /dge gates are ideal for medium and thick sections and can be used on multicavity two plate tools. ,his gate will leave a scar at the parting line. ,he Sub ate is the only automatically trimmed gate on the list. /#ector pins will be necessary for automatic trimming of this gate. *ub gates are quite common and have several variations such as banana gate" tunnel gate and smiley gate to name a few. ,he sub gate allows you to gate away from the parting line" giving more flexibility to place the gate at an optimum location on the part. ,his gate leaves a pin si%ed scar on the part. ,he 'ot Tip ate is the most common of all hot runner gates. Hot tip gates are typically located at the top of the part rather than on the parting line and are ideal for round or conical shapes where uniform flow is necessary. ,his gate leaves a small raised nub on the surface of the part. Hot tip gates are only used with hot runner molding systems. ,his means that" unlike cold runner systems" the plastic is e#ected into the mold through a heated no%%le and then cooled to the proper thickness and shape in the mold. ,he Direct or Sprue ate is a manually trimmed gate that is used for single cavity molds of large cylindrical parts that require symmetrical filling. Direct gates are the easiest to design and have low cost and maintenance requirements. Direct gated parts are typically lower stressed and provide high strength. ,his gate leaves a large scar on the part at the point of contact.

ate !ocation &= <ack to ,op' ,o avoid problems from your gate location" below are some guidelines for choosing the proper gate location&s'?

(lace gates at the heaviest cross section to allow for part packing and minimi%e voids E sink. +inimi%e obstructions in the flow path by placing gates away from cores E pins. <e sure that stress from the gate is in an area that will not affect part function or aesthetics.

!f you are using a plastic with a high shrink grade" the part may shrink near the gate causing gate pucker if there is high molded)in stress at the gate

<e sure to allow for easy manual or automatic degating. Aate should minimi%e flow path length to avoid cosmetic flow marks.

!n some cases" it may be necessary to add a second gate to properly fill the parts. !f filling problems occur with thin walled parts" add flow channels or make wall thickness ad#ustments to correct the flow.

Aates vary in si%e and shape depending upon the type of plastic being molded and the si%e of the part. Barge parts will require larger gates to provide a bigger flow of resin to shorten the mold time. *mall gates have a better appearance but take longer time to mold or may need to have higher pressure to fill correctly.

"all T#ic$ness &= <ack to ,op' (rior to e#ection from the mold" in#ection molded parts are cooled down from manufacturing temperatures so that they hold their shape when e#ected. During the part cooling step of the molding process" changes in pressure" velocity and plastic viscosity should be minimi%ed to avoid defects. @ew aspects are more crucial during this period than wall thickness. ,his feature can have ma#or effects on the cost" production speed and quality of the final parts. Proper "all T#ic$ness& .hoosing the proper wall thickness for your part can have drastic effects on the cost and production speed of manufacturing. hile there are no wall thickness restrictions" the goal is usually to choose the thinnest wall possible. ,hinner walls use less material which reduces cost and take less time to cool" reducing cycle time. ,he minimum wall thickness that can be used depends on the si%e and geometry of the part" structural requirements" and flow behavior of the resin. ,he wall thicknesses of an in#ection molded part generally range from 3mm F 5mm &2.242 F 2.;12'. ,hin wall in#ection molding can produce walls as thin as 2.0mm &2.232'. ,he chart below shows recommended wall thicknesses for common in#ection molding resins.

(niform "all T#ic$ness&

,hick sections take longer to cool than thin ones. During the cooling process" if walls are an inconsistent thickness" the thinner walls will cool first while the thick walls are still solidifying. $s the thick section cools" it shrinks around the already solid thinner section. ,his causes warping" twisting or cracking to occur where the two sections meet. ,o avoid this problem" try to design with completely

uniform walls throughout the part. hen uniform walls are not possible" then the change in thickness should be as gradual as possible. all thickness variations should not exceed ;2G in high mold shrinkage plastics. ,hickness transitions should be made gradually" on the order of 7 to ;. ,his gradual transition avoids stress concentrations and abrupt cooling differences. Alternati)es& !f your part is so complex that you need variations on your wall thickness" look for an alternative. Hou may want to use design features such as coring or using ribs. $t the very least" try not to make the transitions between thicker and thinner sections too abrupt. ,ry using a gradual transition or chamfered corners to minimi%e the dramatic change in pressures inside the mold.

Draft &= <ack to ,op' +ost in#ection molded plastic parts include features such as outside walls and internal ribs that are formed by opposing surfaces of tool metal inside a closed mold. ,o properly release the part when the mold opens" the side walls of the mold are tapered in the direction that the mold opens. ,his tapering is referred to as draft in the line of draw. ,his draft allows the part to break free of the mold as soon as the mold opens. ,he amount of draft required can depend on the surface finish of the mold. $ smooth" polished tool surface will allow the part to e#ect with less draft than a standard tool surface. .onsider the fabrication of the hollow plastic box seen to the right. >nce the plastic has hardened around the mold" the mold must be removed. $s the plastic hardens" it will contract slightly. <y tapering the sides of the mold by an appropriate Idraft angleI" the mold will be easier to remove. ,he amount of draft required &in degrees' will vary with geometry and surface texture requirements of the part. <elow are several rules for using draft properly?

<e sure to add draft to your 7D .$D model before creating radii Dse at least ; degree of draft on all IverticalI faces ; J degrees of draft is required for light texture 3 degrees of draft works very well in most situations 7 degrees of draft is a minimum for a shutoff &metal sliding on metal'

7 degrees of draft is required for medium texture

Sin$ Mar$s &= <ack to ,op' hen the hot melt flows into the in#ection mold" the thick sections donKt cool as fast as the rest of the part because the thicker material becomes insulated by the outside surface of faster cooling plastic. $s the inner core cools" it shrinks at a different rate than the already cooled outer skin. ,his difference on cooling rates causes the thick section to draw inward and create a sink mark on the outside surface of the part" or worse" completely warp the part. !n addition to being unattractive" the mark also represents added stress that is built into the part. >ther less conspicuous areas where sink occurs include ribs" bosses and corners. ,hese are often overlooked because neither the feature nor the part itself is too thick- however" the intersection of the two can be a problem. >ne way to avoid sink marks is to core out the solid sections of the part to reduce thick areas. !f the strength of a solid part is required" try using cross hatched rib patterns inside the cored out area to increase strength and avoid sink. $s a rule)of)thumb" make sure that all bosses and locating6support ribs are no more than 12G of the thickness of the nominal wall. $lso" textures can be used to hide minor sink marks.

Te%tures &= <ack to ,op' ,exturing is a process used to apply patterns to a mold surface. ,his process allows flexibility in creating the final appearance of your parts. ,exturing is an integral piece in overall product development and should be considered during the design process to achieve the desired results. ,exture can be a functional component of design as well. !mperfect parts can be camouflaged by the right texture. !s the part designed for frequent handling? ,exture can be used to hide finger prints and improve the grip for the end user. ,exture can also be used to reduce part wear from friction. $ wide variety of textures are available for in#ection molded parts such as?

Latural6/xotic

+atte @inishes +ulti)Aloss (atterns @usions Araphics Beather Arains6Hides oodgrain" *late E .obblestone Aeometric E Binens Bayered ,extures to .reate Lew Books

!mages or Bogos !ncorporated into the (attern

hen applying a texture to a part" the .$D drawing must be ad#usted to accommodate for this surface variance. !f the texture is on a surface that is perpendicular or angled away from the mold opening then no draft changes are necessary. !f the texture is on a parallel surface with the mold opening" however" increased draft is necessary to prevent scraping and drag marks that could occur during part e#ection. Different textures have different impacts on the molded part. ,he rule)of)thumb when designing for texture is to have ;.0 degrees of draft for each 2.22; of texture finish depth.

Parting !ines &= <ack to ,op' $ parting line is the line of separation on the part where the two halves of the mold meet. ,he line actually indicates the parting plane that passes through the part. hile on simple parts this plane can be a simple" flat surface" it is often a complex form that traces the perimeter of the part around the various features that make up the partKs outer silhouette. (art lines can also occur where any two pieces of a mold meet. ,his can include side action pins" tool inserts and shutoffs. (arting lines cannot be avoided- every part has them. Meep in mind when designing your part" that the melt will always flow towards the parting line because it is the easiest place for the displaced air to escape or vent.

Common Molding Defects &= <ack to ,op' !n#ection molding is a complex technology with possible production problems. ,hey can either be caused by defects in the molds or more often by part processing &molding'

Molding Defects <lister <urn marks .olor streaks &D*'

Alternati)e *ame <listering $ir <urn6Aas <urn

Descriptions 8aised or layered %one on surface of the (lastic part <lack or brown burnt areas on the plastic part located at furthest points from gate Bocali%ed change of color

Causes ,ool or material is too hot" often caused by a lack of cooling around the tool or a faulty heater ,ool lacks venting" in#ection speed is too high (lastic material and colorant isnNt mixing properly" or the material has run out and itNs starting to come through as natural only

Delamination

.ontamination of the material e.g. (( mixed with $<*" very dangerous if the part is being used for a safety ,hin mica like layers formed critical application as the material has very little in part wall strength when delaminated as the materials cannot bond <urrs /mbedded particulates /xcess material in thin layer ,ool damage" too much in#ection speed6material exceeding normal part in#ected" clamping force too low. .an also be caused by geometry dirt and contaminants around tooling surfaces. @oreign particle &burnt material or other' embedded in the part (articles on the tool surface" contaminated material or foreign debris in the barrel" or too much shear heat burning the material prior to in#ection

@lash /mbedded contaminates

@low marks Oetting (olymer degradation *ink marks *hort shot *play marks

@low lines

!n#ection speeds too slow &the plastic has cooled down Directionally Ioff toneI wavy too much during in#ection" in#ection speeds must be set lines or patterns as fast as you can get away with at all times' Deformed part by turbulent flow of material polymer breakdown from oxidation" etc. Bocali%ed depression &!n thicker %ones' (oor tool design" gate position or runner. !n#ection speed set too high. /xcess water in the granules" excessive temperatures in barrel Holding time6pressure too low" cooling time too short" with sprueless hot runners this can also be caused by the gate temperature being set too high Back of material" in#ection speed or pressure too low

Lon)@ill6*hort +old *plash +ark6*ilver *treaks *tringing

(artial part

.ircular pattern around gate +oisture in the material" usually when resins are dried caused by hot gas improperly *tring like remain from previous shot transfer in new shot /mpty space within part &$ir pocket' Lo%%le temperature too high. Aate hasnNt fro%en off Back of holding pressure &holding pressure is used to pack out the part during the holding time'. $lso mold may be out of registration &when the two halves donNt center properly and part walls are not the same thickness'.

*tringiness

Coids

eld line arping

Mnit Bine6+eld Discolored line where two +old6material temperatures set too low &the material is Bine flow fronts meet cold when they meet" so they donNt bond' ,wisting (art Distorted part .ooling is too short" material is too hot" lack of cooling around the tool" incorrect water temperatures &the parts bow inwards towards the hot side of the tool'

Meep these factors in mind when designing your in#ection molded part" and remember that it is easier to avoid problems in the beginning than change your design down the line.

Plastic Part Design

To insure a quality final product, it is necessary to start out with quality components. Injection molded parts can be molded to a high quality standard by focusing on these areas of plastic technology: 1) Correct Part Design 2) Accurate Selection of Material 3) Processing Plastic Processing Only by drawing on expertise from these three areas of plastic technology can a product designer create quality molded parts that maximize performance and are cost effecti e. The purpose of this design guide deals with the first of these three issues ! part design. Correct Part Design Guidelines If there was only one rule for the injection molding process it would ha e to be to maintain uniform wall thic"ness. #ere are some examples of problems associated with part designs that feature a non!uniform wall thic"ness.

Sink marks due to uneven shrinkage

Stress due to

uneven shrinkage

$in" mar"s result from a wall yielding to the still shrin"ing interior mass. % part with non!uniform wall thic"ness will cool une enly, resulting in high molded!in stress.

Voids due to uneven shrinkage

ar!ing due to uneven shrinkage

The already cooled section will not yield to the shrin"ing action of the cooling interior mass causing oids in the thic" portion of the part.

&oncentrated stress at the junction of high ' low shrin"age area may cause a part to warp.

Draft
(lastic parts are always designed with a taper or draft in the direction of mold movement to allow part e#ection or removal from the mold. *ince plastics shrink when cooled" it is common for parts to shrink &or grip tightly' to cores. $ good definition for draft would be? the degree of taper of a side wall or rib needed to allow the molded plastic part to be removed from the metal mold. ithout proper draft" plastic parts may be difficult to remove from the mold. $ draft angle of ;63 degrees is regarded as minimum for most applications. Draft angles of ; ;63 to 3 degrees per side are considered normal for plastic in#ection molding.

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+ibs
+any times the stiffness of a part must increase because of the load applied to the part design. >ne of the easiest ways to cure this problem is change the part geometry by adding ribs. ,he use of ribs is a practical way and economical means of increasing the structural strength of a part. <ut there are guidelines that govern adding ribs without causing sink marks or surface blemishes to your parts.

,- 8ib thickness should be less than wall thickness. $ rib thickness of 12G to 42G of nominal wall thickness is recommended.

.- ,o increase stiffness increase the number of ribs or /gusset plates/" another feature designed to strengthen the plastic part.

0- @or a given stiffness" it is better to increase the number of ribs" not the height. 1- @or thick ribs I core out I the rib from the back. ,his creates a hollow space underneath the part and maintains a uniform wall thickness.

'eig#t& +aximum height of three time nominal wall thickness of part. Spacing& +inimum of two times nominal wall thickness of part between ribs.

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'oles
Holes are easy to produce in molded parts. .ore pins that protrude into the mold cavity make the holes when the part is molded.T#roug# #oles in the molded parts are easier to produce than blind #oles" which do not go all the way through a part.

<lind holes are made by core pins supported on one end only. ,he pins can be deflected and pushed off center by the pressures of the molten plastic material during the molding process. $ good rule of thumb? the depth of the blind hole should be about twice the diameter of core pins up to 76;1I" and up to four times the diameter of core pins over 76;1I. ,he guidelines for blind and through holes are seen below. Blind 'ole 2s#o3n 3it# draft( ) *+ for +iameters (ess than ,-./0 dia. core pins ( ) 1+ for +iameters 2ore than ,-./0 dia. core pins

T#roug# 'ole 2s#o3n 3it# draft( ) 1+ for +iameters less than ,-./0 dia. core pins ( ) /+ for +iameters more than ,-./0 dia. core pins

,here are definite rules for the placement of cored holes in a molded part. !f these minimum distances shown below are not followed" the holes will be egg shaped or the part will deform in the areas around the holes.

,P wall thickness of part DP diameter of hole

$s depicted above" the distance from the edge of a hole to a vertical surface &i.e. rib' or the edge of a part should be twice the part thickness &or more'" or at least one diameter of the hole. ,his same rule applies between holes ) at least two part thicknesses or one hole diameter should be specified.

'oles 2part .$s easy as it is to make holes in molded parts it does not come without some concerns for the strength of the part. @or every cored or molded hole there will be a weld line. ,he weld lines are caused by the flow of the melted plastic around the core pins. ,hese weld lines are not as strong as the surrounding plastic material" and also may detract from the overall appearance of the molded part. ,he part designer should consider these points when designing holes in a molded part.

,he coring of holes is easy when the axis is parallel to the parting line. <ut when holes and other features run perpendicular to the parting line then retractable cores &or cams' are required. *plit pins and cores &called passing steel shutoffs' can be used to create some of the features. ,he designer needs to be aware of the problems of side action cores and the added expenses associated with these types of molds. ith a little understanding of how the mold opens and where the parting line will exist" these costly features can be modified. 8ule of thumb? whenever possible all design features should be incorporated in the same direction of the mold opening so that cam action can be avoided.

Bosses
<osses are used for locating" mounting" and assembly purposes. ,here are boss design guidelines that must be followed to insure the highest quality in molded parts. $gain" one of the main points to consider is nominal wall thickness. ,oo many times bosses are designed with thick wall sections that can affect the appearance of the plastic part and the final product.

8ule of thumb? the wall thickness around a boss design feature &t' should be 12G of the nominal part thickness &,' if that thickness is less than ;64I. !f the nominal part thickness is greater than ;64I the boss wall thickness should be 52G of the nominal wall.

<oss diameter" wall thickness" and height design parameters. hile boss heights vary by design" the following guidelines will help avoid surface imperfections like sink marks and voids? the height of the boss should be no more than 3 ;63 times the diameter of the hole in the boss. (lease observe the I12652I rule &see above' for the wall thickness at the bottom of the boss.

+adii

!n the design of in#ection molded parts" sharp corners should be avoided. *harp corners act as stress risers or concentrators" reducing part strength and causing premature failures. *harp corners may also effect plastic flow" producing parts with ob#ectionable surface flow patterns. Bosses 4 +ibs

Lominal radius should be one quarter of the nominal part thickness" with a minimum radius of .2;0 &i.e. . ;22 wall" 230r'

,P wall thickness of part 8adius ), Corners ,he inside radius should be at least half the part wall thickness.

,he outside radius should equal the inside radius plus the part thickness i.e. .;22 wall and inside radius of .202 equals outside radius of .;02'

Insert Molding Tips

$nother problem concerning high stress occurs with molded)in inserts. ,he plastic melt heats the metal of the inserts. During the cooling stage of in#ection molding" the plastic part cools" but the plastic boss surrounding the metal insert is reheated by the heat from the insert. ,his allows the plastic to continue to shrink around the insert" causing excessive hoop stressQ that will eventually cause the boss to crack. ,he better design and process would be to use ultrasonic insertion or a hot probe &such as a heat staking unit' after the molded part has cooled throughout.

Hoop stress? stress within the circumference of the boss

+eplacing Metal 3it# Plastics

,here are numerous reasons why replacing metal parts with plastic makes sense. (lastics >ne" !nc. has worked with many companies on metal)to)plastic conversions. Here is why plastic may be the best option for your parts. ,5 DEC+EASE PIECE PA+T P+ICES

$ penny saved is a penny earned. $fter initial tooling costs are paid" the piece part pricing is usually much less than the same part produced in metal" whether it be a stamping" casting" or a die cast part ,his cost savings is reali%ed because the in#ection molding process has faster cycle times &more parts made per machine hour' and these parts are identical from one to the other which eliminates secondary machining

.5 E!IMI*ATE TIME6C7*S(MI*

A*D C7ST!8 SEC7*DA+8 7PE+ATI7*S

/liminating secondary operations further reduces costs. (lastic material can be colored with color concentrates before molding ) eliminating secondary painting operations. !n#ection molds can be textured or given various levels of polished surfaces before molding. ,he costly assembly of several metal stampings or castings fastened together can often be replaced by a single in#ection molded part incorporating the features of the total assembly. !f multiple assemblies are required" the plastic parts can have snap)together features to eliminate any fasteners. /liminating sub)assembly tooling or fixtures by using in#ection molded parts can quicken delivery in new product development programs. 7. 8/DD./ (8>DD., /!AH, $LD !+(8>C/ D*/8 /$*/

>ne primary advantage of using plastics instead of metals is weight reduction 8educing product weight with plastics gives you more parts per pound of material" significantly reduces shipping costs and improves the end)userNs physical ease in utili%ing the product $ comparison of the specific gravity values of metals to plastics is shown in the following table?

META!S $luminum 3.0 to 3.4 <rass 4.5 to 4.: .opper 4.4 Rinc 1.S to :.3 *teels :.: to :.47 P!ASTICS (olycarbonate ;.3 to ;.5 Lylon &most types' ;.3 to ;.: (olyethylene .S3 to .S0 (olypropylene .S2 to ;.25 $<* ;.23 to ;.5 15 AI* +EATE+ P+7D(CT ST+(CT(+A! ST+E* T'

,hat third little pig really knew how to choose the right materials to build a strong house. .hoosing plastic over metal gives you products which are light)weight" easier to use and yet possess increased structural strength. (lastic parts can be stronger than metal parts through the use of engineering grade materials. !n addition" the ability to mold in structural strength such as ribs" bosses and gussets when the part is originally produced instead of fastening" welding and gluing operations afterwards can affect the total strength of the assembled part as well as reduce additional costs. 95I*C+EASE 87(+ P+7D(CT DESI * 7PTI7*S DonNt let the design limitations of metals trap you between a rock and a hard place. !ncrease your design options and requirements and still keep costs down. ,he area of greatest difference between metals and plastics is the ease in producing complex shapes. ,he costly assembly of several metal stampings or castings fastened together can often be replaced by a single in#ection molded part incorporating the features of the total assembly. !f multiple assemblies are required" the plastic parts can have snap) together features to eliminate any fasteners. !n#ection molded parts can shorten the time to the market place in new product development programs because of elimination of sub)assembly tooling or fixtures. !f heavy metal shakes" rattles and rolls" then plastic twists and shouts. (lastics are easily processed into complex shapes that would be impossible for metal because plastic materials have non)Lewtonian flow

behavior. ,his means that the viscosity &resistance to flow' will decrease when the flow rate increases. ,he flow rate is increased by increasing the in#ection pressures. ,he standard in#ection molding pressures are 32"222 to 72"222 (si. ,his capability allows plastics to be made to flow to produce thin walled parts with uniform wall dimensions replacing the more costly thicker)walled design features of most metal parts. :5 SA;E D7!!A+S B8 +E6(SI* MATE+IA!S

$ny way you look at it" recycling makes sense. 8e)using materials by adding regrind &ground up runners and scrap parts' to virgin materials generates even more cost savings. (lastic materials fall into two basic types of process groups? ,hermoset and ,hermoplastic. ,hermoset &often called compression molding' is like working with epoxy. >nce the material has been heated and formed in a mold" it is set. ,he material cannot again be processed- it is literally a reaction by temperature or thermally set. /xamples of thermoset materials are $lkyd" (olyesters" +elamine and (henolic. +ost in#ection molding plastics are thermoplastics- that is they can be reprocessed. ,hermoplastics fall into two distinctive molecular groups? amorphous and crystalline. $morphous materials when processed act like honey- that is they never really melt" they #ust soften and are formed under pressure. .rystalline materials act like solder or ice. ,hey have a specific melt temperature and remain a solid until this temperature is reached. $fter the melt temperature is achieved" the materials flow very easily with very low viscosities. hen the material is cooled to a temperature below the melt temperature" the material hardens to a solid form.

Amorp#ous Materials $crylic $<* (olystyrene (C. (olycarbonate

Com!arison Characteristics" $hrin"age 5ase of flow +imensional control of parts .331 ! .3.*-in-in relati ely stiff flowing easier to maintain close dimensional tolerances

Crystalline Materials Lylon (olypropylene $cteal (olyester (olyethylene

.3.* ! .3*4-in-in easy abo e melting temperature more difficult to maintain close dimensional control

<5 I*C+EASE P+7D(CT !I=E

,he ,in +an needed more than a brain to last ) he needed an endless supply of oil as well. 8eplace the environmental vulnerability of metals with the durability and longevity of plastics. +ost plastic materials have greater chemical resistance than most metals. (lastics do not rust or oxidi%e as metals do and most are not affected" as are metals" by acids or base compounds.

Design

uidelines for Metal to Plastic Con)ersions

,here are several common mistakes made when replacing a metal product with a plastic molded part. ,he new part design must adhere to specific material and molding process guidelines. *everal of the general guidelines are shown below?

*ee guidelines for uniform wall thickness when coring out sections

*ee Draft section for design specifications

Design Auidelines
(niform 3all t#ic$ness
.onsistent wall thickness for plastic parts to minimi%e the potential for warped or distortion.

*ink +arks all ,hickness by +aterial Auideline $void arping 8ib6<oss to all ,hickness 8atio (art Draft on (lastic !n#ection +olds
Sin$ Mar$s
$s the plastic in the mold cools from the outside it can cause pulling on outer walls resulting in sink marks. ,hinner wall thickness will help to prevent this. here possible always try to design a part with thinner and consistent wall sections to minimi%e warp and sink marks.

"all T#ic$ness by Material

uideline

,he proper material selection for your desired part thickness can also help. *ee table below for in#ection moldable material selection and recommended wall sections for your molding pro#ect.

$<* $cetal $crylic Biquid crystal polymer Bong)fiber reinforced plastics Lylon (olycarbonate (olyester (olyethylene (olyphenylene sulfide (olypropylene (olystyrene (olyurethane

2.250 ) 2.;52 2.272 ) 2.;32 2.230 ) 2.022 2.272 ) 2.;32 2.2:0 ) ;.222 2.272 ) 2.;;0 2.252 ) 2.;02 2.230 ) 2.;30 2.272 ) 2.322 2.232 ) 2.;42 2.230 ) 2.;02 2.270 ) 2.;02 2.242 ) 2.:02

@iber reinforced plastic allows for larger thicker parts (art arp !n addition" because thinner sections will free%e faster than thicker sections there is also the possibility of stresses building up between thick E thin sections" resulting in part warp.

A)oid "arping
;. 8educing transitions between ,hick and thin sections. 3. use gussets and ribs instead of thick sections. /ven small transitions like this can cause warp

+ib>Boss to "all T#ic$ness +atio

8ibs and <osses protruding from wall thickness should follow this rule of thumb.

12G of wall thickness.

Tip& 8educe the <oss diameter and strengthen with ribs

Part Draft on Plastic Injection Molds

(lastic parts should be designed with draft to prevent sticking and e#ector pin push marks on the show surface during the molding process. $lso" an adequate amount of draft is needed for surfaces that will be textured. DonNt forget ribs should not exceed 12G of wall thickness.