13 Design For Injection Moulding

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PDN 505
Session 13
Design for Injection Moulding
Lecture delivered by
Prof. M. N. Sudhindra Kumar
Professor MSRSAS-Bangalore
Sudhindra MSRSAS
M.S Ramaiah School of Advanced Studies - Bangalore 1

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Session Objectives
At the end of this session the delegate would have understood
Applying DFM to Injection-Molding Thermoplastic Parts
Properties of Thermoplastic materials and its process
Characteristics of Injection molded parts and its effects
Different way of designing injection molded parts through
the Design recommendations
Manufacturability of plastic parts
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Session Topics
Thermoplastic materials
The Manufacturing Process
Typical Characteristics of Injection- Molded Parts
Effects of Shrinkage
Economic Production Quantities
Design Recommendations
Design Guidelines
Computer Simulations of Injection-Molding
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Dimensional Factors And Tolerance Recommendations

Design for Manufacturability

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Thermoplastic materials
Synthetic
Organic chemical compounds
High molecular weight?
They soften or liquefy when they are heated and solidify

when they are cooled.
When cooled, they are relatively tough and durable and

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suitable for a wide variety of product applications.

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Mold?
Molding?
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THE PROCESS:
The plastic material is received by the molder in
granular form???
It is placed in the hopper of an injection-molding

machine, from which it is fed to a heated cylinder.
Mold defines final shape as material cools and

solidifies
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THE PROCESS:
As the granules heat in the cylinder, they melt,
or plasticize(Tg)
A typical melting temperature is about 180C

(350F), although this varies with different
materials and molding conditions
The mold, usually of steel, is clamped in the

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machine and is water-cooled

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THE PROCESS:
The mold is opened, and the molded part with its
attached runners is removed
The process, with the occasional exception of

part removal, is automatic
It requires about 45 s/cycle, more or less, with

most of that time being devoted to cooling of the
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material in the mold

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THE PROCESS:
Very high pressures, on the order of 70,000 kPa
(10,000 lbf/in2) or more, are required during
injection.
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Can this assembly be replaced by a single piece molded

design?
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TYPICAL CHARACTERISTICS OF
INJECTION- MOLDED PARTS:
Intricate parts in large quantities
One molded part can replace what would

otherwise be an assembly of components
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Characteristics of injection- molded parts:
Color and surface finish often can be molded directly

onto the part, so that secondary finishing operations are
not necessary(Painting???)
Generally thin-walled.
Heavy sections and variable wall thicknesses are

possible, though they are normally not recommended.
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Generally less strong than metals
More apt to be found in less highly stressed applications
Housings and covers are common uses rather than, for

example, frames and connecting rods.
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Gradually being developed with better and better

strength characteristics and are increasingly finding
themselves used for moving parts and in more structural
applications (Engine Parts???)
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Some Engineering plastics
Nylon
Polycarbonate
Acetal
Phenylene oxide
Polysulfone
Thermoplastic polyesters & others, particularly
when reinforced with glass or other fibers, are
functionally competitive with zinc, aluminum,
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and even steel.

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Effects of Shrinkage
All thermoplastics exhibit shrinkage on cooling and
solidification
Causes various irregularities and warpage in the molded
part
Most common such defect is the sink mark,

or surface depression, opposite heavy sections.
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One Effect of Shrinkage

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Second Effect of Shrinkage

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Third effect of shrinkage

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ECONOMIC PRODUCTION QUANTITIES:
>10,000
A unique mold for each part
Production must be large enough so that the mold

cost can be amortized over the quantity
manufactured.
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Relationship between Mech.

Properties of Plastics &
Moldability
Mechanical Moldability
Properties
Low (PE, PP, PS) High
High (PC, Alloyed Low
Grades..)
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Suitable Materials:
PVC, though low in cost and having very good

physical properties, is more difficult to injection-
mold than many other materials
PVCs prime drawback is a narrow temperature

range between its melting and degradation points
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Properties,Cost & applications of Thermoplastics

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DESIGN RECOMMENDATIONS:
Gate and Ejector-Pin Locations
The designer(?) should consider the location of these elements
Ejector pins usually can be located on the underside of a part if it

has an outside and an underside
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Various Gating systems

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(Difference?)
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No weld
Thin line for
part circular
part!
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Gate and Ejector-Pin Locations
Desirable gate locations for trouble-free mold filling
Center gating of round and cylindrical parts
Near-center gating of other large-area parts

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Suggested Wall Thickness

Generally, thinner walls are more feasible
with small parts rather than with large ones
The limiting factor in wall thinness is the

tendency for the plastic material in thin walls to cool and
solidify before the mold is filled
The shorter the material flow, the thinner the wall can
be(?)
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Suggested Wall Thickness
Walls also should be as uniform in thickness as possible

to avoid warpage from uneven shrinkage.
When changes in wall thickness are unavoidable, the

transition should be gradual, not abrupt.
(See next Slide)
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Redesign
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Comment on this design

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Design Recommendations:
Holes
Holes are feasible in injection-molded parts but are a
complicating factor in mold construction and part
quality
"Knit" or "weld" lines adjacent to the hole often

develop, and flashing also may occur at the edge of the
hole. (See next slides)
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Holes
Minimum spacing between two holes or between
a hole and side-wall should be one diameter.
Comment on this design?

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Holes
Minimum spacing between two holes or between a hole
and side-wall should be one diameter.
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Design Guidelines:
Holes
A through hole is preferred to a blind hole
Why?
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Design Guidelines:
Holes
A through hole is preferred to a blind hole
Because the core pin that produces the

hole can then be supported at both ends
Resulting in better dimensional location of

the hole and avoiding a bent or broken pin.
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Design Guidelines:
Holes
Holes in the bottom of the part are preferable to

those in the side because the latter require
retractable core pins
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Design Guidelines:
Holes
Blind holes should not
be more than two
diameters deep. If the
diameter is 1.5 mm
or less, one diameter is
the maximum practical
depth.
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Design Guidelines:
Holes
Blind holes should not
be more than two
diameters deep. If the
diameter is 1.5 mm
or less, one diameter is
the maximum practical
depth.
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To increase the depth of a deep blind hole, use

steps. This enables a stronger core pin to be
employed.
?
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To increase the depth of a deep blind hole, use

steps. This enables a stronger core pin to be
employed.
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Similarly, for through holes, cutout sections in

the part can shorten the length of a
small-diameter pin. (See Fig. 6.2.13.)
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Similarly, for through holes, cutout sections in

the part can shorten the length of a
small-diameter pin. (See Fig. 6.2.13.)
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Use overlapping and offset mold-cavity projections

instead of core pins to produce
holes parallel to the mold-parting line (perpendicular to
the mold-movement direction).
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Comment on this design

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Design Guidelines:
Ribs
Reinforcing ribs should be thinner than the wall
they are reinforcing
To prevent sink marks in the opposite side of the
wall.
Recommended rib thickness : Between 40% and
60% of the wall thickness.
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Design Guidelines:
?
Ribs should not be higher than 2.5 to 3.0 times
the wall thickness.
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Design Guidelines:
Ribs should not be higher than 2.5 to 3.0 times

the wall thickness.
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Design Guidelines:
Ribs
Two ribs may be used, if necessary, to provide
the extra reinforcement that would otherwise be
provided by a high rib.
The ribs should be two or more wall thicknesses

apart (??)
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Design Guidelines:
Ribs
Two ribs may be used, if necessary, to provide
the extra reinforcement that would otherwise be
provided by a high rib.
The ribs should be two or more wall thicknesses

apart
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Design Guidelines:
Ribs
Ribs should be perpendicular to the parting line
to permit removal of the part from the mold.
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Sink marks caused by ribs can be disguised or

hidden by grooves or surface texture opposite the
rib.
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Sink marks caused by ribs can be disguised or

hidden by grooves or surface texture opposite the
rib.
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Design Guidelines:
Ribs should have a generous draft of 0.5deg to
1.5 deg per side
There should be a radius at the base of 25% to
40% of t
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Design Guidelines:
Bosses
Protruding pads used to provide mounting
surfaces or reinforcements around holes
If large bosses are needed, they should be

hollow for uniformity of wall thickness.
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Ribs aid material Flow for a boss

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Design Guidelines:
Bosses
Bosses in the upper portion of the mold can trap
gases and should be avoided
If possible, locate bosses in corners,to aid

material flow in filling the mold.
If a detached boss is necessary, a connecting rib

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will aid material flow

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Undercuts
Undercuts are possible with injection-molded
thermoplastic parts, but they may
require sliding cores or split molds
External undercuts can be placed at the parting

line or extended to the line to obviate the need for
core pulls
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Look at the design of ball pen cap

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COMMENT ON THIS DESIGN

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UNDERCUT
Shallow undercuts often may be strippable from
the mold without the need for core pulls.
If the undercut is strippable, the other half of the
mold must be removed first.
Then the mold ejector pins can act to strip the
part.
Next Slide shows the average maximum
strippable undercut for common thermoplastics.
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Sequence of actions before stripping?

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Hex Screw???
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Ways of molding threads:

Use a core that is rotated after the molding cycle has
been completed. This unscrews the part from the mold
Put the axis of the external screw at the parting line of

the mold,avoiding the need for a rotating core but
necessitates a very good fit between mold halves to avoid
flash across the threads(Omit threads in the area of the
parting line)
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If threads with strong holding power are needed, use
metal inserts
Internal threads can be tapped in almost all

thermoplastics, and if the thread diameter is small [5 mm
(3/16 in) or less], tapping is usually more economical than
molding
Self-tapping screws are preferable to tapped or molded

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threads and a conventional screw

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Make the threads a few, shallow, and of rounded form so
that the part can be stripped
from the mold without unscrewing.
A coarse thread with a somewhat rounded form is

preferred for all screw threads because of ease of filling
and avoidance of featheredges even if it is removed by
unscrewing.
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What should we do to strip the bolt from

mold?
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Nomenclature of thread shape???

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Design of Inserts:
Inserts are useful and practical to provide reinforcement
where stresses exceed the strength of the plastic material
Sharp comers should be avoided on the portion of the
insert that is immersed in the thermoplastic.
Knurls on machined inserts should be relatively coarse
to permit the material to flow into the recesses
There should be a smooth surface where the insert exits
from the plastic
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The surface exiting from plastic should be smooth

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Seal off plastic from unwanted areas

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???
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???
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Not sufficiently embedded

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in plastic

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Sketch a screw driver

as being molded
Detail the embedded portion inside the

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polymer handle

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?
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Lettering:
The lettering on the part generally should be
raised ??
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Lettering:
The lettering on the part should be raised (ie) formed by
depressed, engraved letters in the mold
It is easier to engrave lettering in a mold cavity than it is

to machine away the background and leave raised letters.
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Lettering:
Sometimes it is desired to have depressed letters on the part and to
fill them with paint that contrasts with the color of the plastic
material
Cavities for filled lettering should be sharp-edged and 0.13 to 0.8

mm wide
They should be one-half as deep as wide and should have a

rounded bottom.
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Draft: ?
Usually, deep parts require less draft angle than shallow
parts
For shallow parts draft should average 1/2deg or

more
For deep parts 1/8deg can often be satisfactory

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Textured surfaces require greater draft.

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Draft:
It is highly desirable to incorporate some draft, in the
side walls of injection molded parts to facilitate removal
of the part from the mold.
Drafts as low as 1/4deg are often adequate.
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Draft:
Usually, deep parts require less draft angle than shallow
parts
For shallow parts draft should average 1/2deg or more
For deep parts 1/8deg can often be satisfactory
Textured surfaces require greater draft.

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Minimum Drafts for some common Materials

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Corners: Radii and Fillets

Sharp corners should be avoided except at the parting
line.They interfere with the smooth flow of material and
create possibilities for turbulence with attendant surface
defects.
Sharp comers also cause stress concentrations in the
part that are undesirable from a functional standpoint.
Fillets and radii should be as generous as possible. A
desirable minimum under any circumstance is 0.5 mm,
while 1.0 mm is a preferable minimum if part
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requirements permit

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Surface Finish
Surface polish or textures can be molded into the part.
No secondary surface-finishing operations
(except, of course, plating, hot stamping, or painting, if
desired) are necessary
High-gloss finishes are feasible if the mold is highly
polished and if molding conditions are correct
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Surface Finish
However, dull, matte, or textured finishes are preferred to
glossy finishes, which tend to accentuate sink marks and
other surface imperfections.
Painting of most thermoplastics is feasible but is not
recommended if the color can
be molded into the part.
The latter approach obviously is more economical and
gives superior results.
If contrasting colors are required, masks can be
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fabricated and a portion of the part left unpainted.

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PLATING OF PLASTIC PARTS:

Feasible for some plastics but is a specialized operation.
Surface decorations such as flutes, reeds, and textures
should stop short of the parting line so that any parting-
line flash is easy to remove.
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Comment

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Flat Surfaces:
Flat surfaces are somewhat more prone to show
irregularities than gently curved surfaces
Since the latter also produce more rigid parts, they are
preferable
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Mold Parting Line:

Every injection-molded part shows the effect of the
mold parting line, the junction of
the two halves of the mold.
The part (and the mold) should be designed so that the
parting occurs in an area where it does not adversely
affect the appearance or function of the part.
One easy way to do this is to put the parting line at the
edge of the part where there is already a sharp corner
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Comment on this positioning of parting line?

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Two reasons???
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On parting-line:.
Parting lines should be straight; i.e., the two mold halves
should meet in one plane only.
This obviously provides more economical mold
construction, but it may not be possible if the part design is
irregular.
If it is not possible to place the parting line at the edge of
the part, cleaning parting line flash is facilitated by having
a bead or other raised surface at the parting line as shown
in slide
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Comment on the design of parting line

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On Parting Line:
Deliberately offset cavities are helpful in avoiding
appearance defects, which may occur if the two mold
halves do not line up properly.
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Comment on the design of parting line, where the two

mold-halves do not lineup properly?
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Computer Simulations of Injection-Molding

Invaluable to both the product designer and tool
designer.
Aid in optimizing the material flow in the mold & help
avoid or minimize molding problems like shrinkage,
warpage, weld lines, and sink marks.
Changes in both the mold and the part may result from
such a simulation.
Problems can be identified before the mold is actually
machined.
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DIMENSIONAL FACTORS AND TOLERANCE

RECOMMENDATIONS:
Dimensions cannot be held with the precision obtainable
with close-tolerance machined metal parts, due to
1. There is materials shrinkage,including variation and
unpredictability in the shrinkage.
2. Plastics exhibit a high thermal coefficient of expansion.
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3. Despite automatic-control apparatus for pressure,

temperature, and time settings,
there is some variation in these factors from cycle to
cycle, resulting in slight dimensional variations in
molded parts.
4. Mold runners, cooling channels, and gates cannot
always be located in the optimal
position, leading to differences in how uniformly the
material is "packed" in the mold and how uniformly it
cools. Some distortion or built-in stresses are
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unavoidable.

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Plastic parts are usually more flexible than metals.A

corollary of the flexibility factor is a lessened need for
very close tolerances.
Plastic parts, when assembled, often can be deformed
slightly if this is necessary to ensure a good fit.
Knowledgeable designers take advantage of this fact by
designing lips and locating bosses on plastic parts to
ensure alignment with mating-part surfaces when
necessary.
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As with other processes, close dimensional tolerances

can greatly increase the cost of injection-molded parts.
Fine-tolerance molds are costlier than looser-tolerance
molds. There are processing-cost increases as well when
extra tight dimensional control is needed.
For example, closer process controls are needed for

pressure, temperature, and cycle time; cycle time may be
increased; shrink fixtures may be required after the part
has been removed from the mold; and scrap rates will be
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higher.

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Different plastics materials have different tolerance

capabilities. Low-shrinkage
materials can invariably be molded with 'closer tolerances.
Glass-or mineral-filled
materials can be molded more accurately than unfilled
materials.
Cost
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Tolerance
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INJECTION-MOLDED THERMOPLASTIC
PARTS:
The use of a greater number of mold cavities
tends to reduce the closeness of
dimensional control over the molded parts. As a
rule of thumb, for each cavity after
the first, allowable dimensional. tolerances
should be increased by 5 percent.
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For example,
a single-cavity mold with an allowable tolerance of +/-
0.1 mm (0.004 in) on
a particular dimension should have +/- 0.15 mm (0.006
in) if the number of cavities is
10 (10X5 percent = 50 percent increase in tolerance).
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Tables 6.2.4 and 6.2.5 show suggested values for

dimensional tolerances for various plastic materials.
These tables, developed from data supplied by the
Society of the Plastics Industry, represent historic and
customary practices prevailing in the plastics-molding
industry. Contract forms or other agreements of
individual molders may vary.
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Design for Manufacture/Assembly

After Product DFM Analysis through DFA design each part
for manufacturability.
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Product DFM through DFA is the cake.

Part DFM is the icing on the cake.
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Quality of Design FORM, FIT FUNCTION
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Summary
Injection moulding is extensively used to produce intricate parts for
engineering and commercial applications from polymer granules
Colour , surface finish and even printing often can be obtained directly in
moulding without the need of secondary operations
Design principles for design of moulded parts need to be followed to
obtain required dimensions, avoid component warpage and surface
defects particularly uniform wall thickness, design of ribs and bosses
Injection moulds need to be designed with appropriate injection,gating
and ejection systems, adequate drafts and air vents,heating and cooling
systems, with provision for insert moulding and side cores as required
Injection moulding requires good control on processing parameters to
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obtain consistent quality, but produce components with very good part
detail, finish and dimensional consistency at a very low cycle time

13 Design For Injection Moulding

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M.S Ramaiah School of Advanced Studies - Bangalore 1

M.S Ramaiah School of Advanced Studies - Bangalore 2

Dimensional Factors And Tolerance Recommendations

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Organic chemical compounds

High molecular weight?

They soften or liquefy when they are heated and solidify

When cooled, they are relatively tough and durable and

suitable for a wide variety of product applications.

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It is placed in the hopper of an injection-molding

Mold defines final shape as material cools and

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A typical melting temperature is about 180C

The mold, usually of steel, is clamped in the

machine and is water-cooled

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The process, with the occasional exception of

It requires about 45 s/cycle, more or less, with

material in the mold

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Can this assembly be replaced by a single piece molded

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Intricate parts in large quantities

One molded part can replace what would

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Characteristics of injection- molded parts:

Color and surface finish often can be molded directly

Heavy sections and variable wall thicknesses are

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Characteristics of injection- molded parts:

Generally less strong than metals

More apt to be found in less highly stressed applications

Housings and covers are common uses rather than, for

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Characteristics of injection- molded parts:

Gradually being developed with better and better

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Characteristics of injection- molded parts:

and even steel.

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Most common such defect is the sink mark,

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One Effect of Shrinkage

Second Effect of Shrinkage

Third effect of shrinkage

ECONOMIC PRODUCTION QUANTITIES:

A unique mold for each part

Production must be large enough so that the mold

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Relationship between Mech.

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PVC, though low in cost and having very good

PVCs prime drawback is a narrow temperature

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Properties,Cost & applications of Thermoplastics

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Ejector pins usually can be located on the underside of a part if it