DESIGN FACTORS TO IMPROVE MOULDEABILITY UNDERSTAND THE FOLLOWING

Gate • Ideally at geometric center of the part.

Wall Thickness
Pressure drop in runner
system
Flow pattern
Melt temperature variation
in side mold
Filling Pressure
Maximum Shear Stress
Melt stream velocity
Avoid hesitation effect
Weld-lines
Hold-on pressure
Thermal shut off of runners.
Heat exchange
Core and Cavity dimensions
Easy ejection
• Melt stream shape is similar to projected shape of the part by multiple gate or suitable type and size of the gate.
• Locate gate at thickness section so that melt flow from thick to thin section
• No variation in wall thickness. Larger the variation means poorer mouldability. Rib thickness 50 -60% of wall thickness
• Runner system should be designed for high pressure drop, thus minimizing material in runner, in order to give low runner to part weight
ratio.
• Distance (L/T ratio) from gate to boundary in all direction, if not same, provide flow leaders or flow deflectors to balance the flow to
improve mouldability.
• Lower the difference in L/T ratios in different direction, better the mouldability.
• Variation of melt temperature should be with in 10 degree centigrade. Shearing through narrow wall increases melt temperature.
• The good mouldability occur when pressure gradient i.e. pressure drop per unit length, is constant along the flow path.
• The shear stress during filling should be less than a critical value. This critical value depends on material and application. This data is
available with Moldflow software.
• Ideally, all melt streams move at same velocity. This can ensure same cooling time for all melt streams.
• Difference in velocities as less as possible for better mouldability
• Melt flow from thick to thin section is better for mouldability.
• Weld-line distance from gate should be as less as possible for better mouldability.
• Weld line can be shifted by using frame of suitable thickness.
• Multi steps with reducing pressure with time to avoid molded-in stress near the gate.
• The runners must be sized for thermal shut off when the cavity is just filled and sufficiently packed, to avoid overpack or reverse flow, in
and out of cavity, after the mold is filled.
• Consistent mold temperature can only be ensured when there is balance between heat in and heat out during molding cycle time. Cooling
channels must be designed with the help of Mold Flow software. This should ensure uniform cooling time to enhance mouldability.
• Core and cavity Dimensions computed taking into consideration mold-makers tolerance, mold shrinkage and post molding shrinkage.
• Proper taper on the part and smooth polished mold surface facilitate easy part ejection.
PLASTICS PART DESIGN GUIDE

API engineers and designers can work with you to develop and design your plastic injection moulded component. To ensure a quality part, there are three major areas of focus
throughout the design stage:

Proper plastic part design

Proper material selection plastic part design
Processing conditions for plastic injection moulding

The designers and engineers at API have over 250 combined years of experience in designing parts for plastic injection moulding, selecting materials, and processing resins (specializing
in engineering and high performance resins). This guide was designed to demonstrate the basic elements of proper plastic part design.

DESIGNING PARTS FOR UP & DOWN MOLDING HELPS CONTROL COST

Designing a part that can be moulded with a "straight pull" or "up & down" motion is a great way to keep the cost of the mould down. A straight pull mould is designed so that when
the two halves (A side and B side) of the mould separate from each other, there is no plastic blocking the path of the metal in the direction of the pull. Undercuts on the part cause this
blockage of path and require an action in the mould (cams, core pulls, etc.). Action in the mould can have a major impact on the cost (and overall size) of a mould.

UNIFORM WALL THICKNESS HELPS TO PREVENT DEFECTS

Proper wall thickness is one of the most fundamental requirements in designing a part for plastic injection molding. Plastic shrinks as it cools which can lead to defects such as sink
marks, voids, stresses, and warping. Plastic resin solidifies in the mold nearer to the outside of the part (closest to the mold surface). Thick sections of a part tend to pull inward,
creating stresses, sink marks, or voids. Since thinner sections cool quicker, stress can build in the part between thinner and thicker sections, resulting in part warpage.
DRAFT ALLOWS FOR PARTS TO RELEASE FROM THE MOLD

Draft is required on all parts in the direction of mold movement in order to allow parts to release or eject from the mold properly. Draft is the angle in which the part is tapered to allow
it to release. As the part cools, it tends to want to shrink to the core side of the mold. Adding draft helps the part to release. Most parts or applications require a minimum of 1/2 to 1
degree, however 11/2 to 2 degrees is widely accepted as the norm.

Draft angles allow for removal of the plastic from the mold. Without draft angles, the part would offer significant resistance due to friction during removal. Draft angles should be
present on the inside and the outside of the part. The deeper the part, the larger the draft angle. A simple rule of thumb is to have a 1 degree draft angle per inch. Not having enough
draft angle may result in scrapes along the sides of the part and/or large ejector pin marks (more on this later).

HOLES ENHANCE PART FUNCTIONALITY AND REDUCE WEIGHT

Holes can be added to a part for functionality or to reduce overall part weight (coring). Core pins are typically used to form a hole, preventing the molten plastic from filling in that
space. Through holes go all the way through a part. Blind holes do not completely go through a part. Core pins for a blind hole are only supported by one end, so there is a greater
degree of difficulty in forming them without defect. Forming holes can lead to defects or have a negative impact on aesthetics. Since the molten plastic flows around the core pin, it can
leave a weld line (which may be visible and/or be weaker than the remainder of the part).

1. The depth of a blind hole should be about two times the diameter of the core pin for small pins (less than 3/16") and four times the diameter of the core pin for pins greater than
3/16".
2. Distance from the edge of a hole to a vertical surface (edge or part or rib) or another hole should be at least two times the thickness of the part or at least the diameter of the core
pin (hole).
3. Holes created in the direction of the opening/closing of the mold or parallel to the parting line are relatively easy to produce. Holes at different angles can be created, but may
require special action in the mold utilizing core pulls or cams which can have significant cost impacts.
BOSSES AID IN ASSEMBLY AND MOUNTING

Bosses can be added to the part design for assembly, locating, or mounting of a part. Improper placement of a boss leads to uneven wall thickness and can have a negative impact on
the aesthetics, shrinking, or strength of a part.

Wall thickness around a boss feature should be 55%–65% of the nominal wall thickness for thin walls (less than 1/8") or around 40% of the nominal wall thickness if greater than 1/8"
Boss height should be no more than 2 1/2 times the diameter of a hole in the boss.
BOSSES AID IN ASSEMBLY AND MOUNTING

Bosses can be added to the part design for assembly, locating, or mounting of a part. Improper placement of a boss leads to uneven wall thickness and can have a negative impact on
the aesthetics, shrinking, or strength of a part.

Wall thickness around a boss feature should be 55%–65% of the nominal wall thickness for thin walls (less than 1/8") or around 40% of the nominal wall thickness if greater than 1/8"
Boss height should be no more than 2 1/2 times the diameter of a hole in the boss.

RIBS ENHANCE PART STRENGTH AND STABILITY

Ribs can be added to parts to add rigidity or stiffness. Adding ribs allows for a part to increase strength and bear a
higher load. Ribs too have recommended guidelines to maximize functionality and minimize defects.

1. Rib thickness should be less than the wall thickness. Recommended thickness is 60% to 80% of the nominal
wall.
2. Adding more ribs adds more strength or stiffness to a part. It is better to add more ribs than make larger or
thicker ribs.
3. Ribs should be spaced at least two times the nominal wall thickness from one another.
4. Rib height should be less than three times the nominal wall thickness of the part.
5. If a thick rib is required, the center of the rib should be cored (cut out) to allow for uniform wall thickness.

Support ribs/gussets are used to give a product’s walls additional support. They are used mainly in two situations:
(1) where the part has 90-degree angled walls that meet, and (2) where a part may be too long or large and the
wall thickness leaves the part flimsy or weak. Support ribs tend to work best in the direction in which they are
needed, such as running the length of a long section. When designing support ribs, it is important to consider
draft angles and base thickness at no more than ⅔ the thickness of the wall it is attached to.
ADDING A RADIUS REDUCES STRESS ON CORNERS

Radii should be added to angles to prevent sharp corners. Corners can lead to stresses, limit material flow, and often reduce part strength.

1. Inside radius of a corner should be at least half of the wall thickness

2. Outside radius of a corner should be equal to the part thickness plus the inside radius
3. A radius being added to a boss or rib should be 1/4 of the part thickness, no smaller than .015

Material selection and processing conditions are equally important factors in the proper design for a plastic injection molded component or part.

Radiused Edges

Having radiused edges and corners (both inside and outside) of a part is a multipurpose feature. This allows for better removal during part ejection, — in conjunction with drafted
sides — and better material flow (more on this later). Most importantly, however, is that it will not only prevent excessive expenses when creating the mold, but it will prevent cracks
from forming due to stress concentration.

Keep in mind that radiused corners should maintain same wall thickness, which means that if inner r=½ thickness then outer R=3*½ thickness.
Undercuts

Undercuts are items that interfere with the removal of either half of the mold. Undercuts can appear just about anywhere in the design. These are just as unacceptable, if not worse
than a lack of a draft angle on the part. However, some undercuts are necessary and/or unavoidable. In those instances, necessary undercuts are produced by sliding/moving parts in
the mold. Keep in mind that creating undercuts is more costly when producing the mold and should be kept to a minimum.

Solid vs Shell

As the plastic cools in the mold, it also shrinks, which is a common characteristic for most
materials.

Making a component a shell versus a solid helps reduce the amount of shrinkage or
warpage that happens during the cooling process. It also helps lowers the cost of material
needed to be used in that part. There are numerous ways to shell a design, one example is
shown on the sphere below.
Sink Marks

Sink marks are as they sound, a spot or segment of the plastic

surface that appears and/or feels as if it has sank into the part.
These marks are caused by a number of items:

• inconsistent wall thickness (may also lead to voids);

• bad radius in corners;
• thick support ribs (to be discussed later);
• sharp corners;
• not shelling parts out.

Connecting Parts Together

Products are generally composed of two or more parts connected together. These parts can be connected
with mounting bosses, snap hooks, screws, etc. A common way of uniting two parts is using screws through
mounting bosses. Having lips/grooves where the parts touch is a common way to align parts together.

When planning on how parts will connect, keep in mind all the previous tips throughout this presentation,
such as draft angles, shelled parts, support ribs/gussets, etc.
Part Lines

Part lines are where the two halves of the mold meet. This generally creates a
physical line on a part that is both visible and noticeable to the touch. These
lines, however, can be hidden or minimized when placed along edges of the
part. When designing a part, always keep in mind its part lines.

Ejector Pin Locations

Ejector pins are what allow the part to be removed from the mold. These pins
literally push the part out after the material has been injected into the mold
and set. However, while pushing parts out, these pins leave marks on the
part. These marks are generally not removable, so location is key to keep in
mind when designing the part
Gate Locations and Material Flow

Along with ejector pin locations and part lines, it is also important to know where to
have the gate locations. Gates are where the molten plastic enters the cavity of the
part in the mold. These gates, once the part cools, leave a mark/ indication of where
the gate was, even when attempted to be removed by a post process. Gate location
is sometimes determined by:

• where it will be less noticeable;

• where it will not interfere with the rest of the part;
• how the plastic material will flow evenly through the part;
• or a combination of all these.

Material and Thickness

Depending on (1) how the product works, (2)

the environment it will be in and (3) the
preference of the designer, a material should be
selected. These materials change how the part
feels, looks and operates. Some are flexible,
some are rigid, some are strong, some are
brittle. The type of material chosen will often
have a significant effect on the design of the
part. Some support ribs may need to be
removed or added, walls may need to be thicker
or thinner, etc.
Material and Thickness

Depending on (1) how the product works, (2) the environment it will be in and (3) the preference of the designer, a material should be selected. These materials
change how the part feels, looks and operates. Some are flexible, some are rigid, some are strong, some are brittle. The type of material chosen will often have a
significant effect on the design of the part. Some support ribs may need to be removed or added, walls may need to be thicker or thinner, etc.
Conclusion

All the concepts presented in the previous slides make up just some of the good practices an engineer has to keep in mind when designing parts to be mass manufactured by
means of injection molding.

These practices are also known as DFM (Design For Manufacturability) and should be used as a checklist constantly throughout the design and redesign of products.

Remember, keeping these practices in mind will ensure long-term savings in manufacturing costs and time for customers.

10 Things to Consider When Designing Plastic Parts for Injection Molding

Whenever you begin a design project involving plastic parts, where your end goal is to have the component injection molded, you'll want to consider some things on the front end of
your design process that will allow for time and money to be saved during the production phase of your project. This foresight at the beginning stages of product design will be useful in
understanding the limitations and challenges faced by the manufacturers of your product.

These 10 considerations are by no means exhaustive when considering the best plastic injected part design, but they will for sure get you very close to where you need to be and at the
very least, point you in the right direction. So let's check out these helpful tips:

1. Consider the Parting Line

Try and imagine your part being molded. It can be difficult for some to think in the "negative", and by that I mean visualizing the empty cavity space that the liquid plastic will fill in
order to mold into a plastic part. Inevitably, once that cavity space is filled, your part will have to be ejected from that space. In order for that to happen, the two mold halves will have
to separate, leaving behind your plastic injected part in one side of the mold (preferably the side where you plan on ejecting from). You need to visualize and plan for where this
"parting line" will be so as to ensure that your part does not get trapped in the mold.

2. Avoid Undercuts (If Possible)

Undercuts on your part wont necessarily make it more difficult to mold your part, but rather more difficult to demold. The undercut portion of the plastic part will get trapped inside
your mold once the part is cooled and hardened, and in turn making it impossible to eject from the mold without other mold actions. Many times, undercuts are a necessity for part
function. Side actions and lifting mechanisms will have to be introduced to your tool in order to deal with the ejection of your part. Sometimes this is not avoidable, but if you are
looking to save on tooling cost, it might be worth trying to redesign in order to eliminate necessary tooling costs.
3. Uniform Wall Thickness
You want to make sure that you try and make the wall thickness of your part as consistent as possible. It's alright if you don't have uniform wall thickness to some extent, but uneven
wall thickness greatly increases the likelihood of sink marks, warpage, voids, molded-in stress, longer cooling times, and even material flow restrictions. If wall thickness must be
uneven, it is best to have smooth transitions that taper over some distance. The size of the part and the ability of the material to fill will determine the minimum wall thickness allowed
for your plastic injected part. ​

4. Shrinkage and Warpage Considerations

All materials shrink at different rates and at varying degrees within the cooling process of your injection molding operation. Shrinkage and warpage are two different phenomena that
can occur. Shrinkage occurs where there is a difference between corresponding linear dimension of the mold and the molded part. Warpage is a dimensional distortion in a molded
plastic caused by excessive residual stress in the part. There are various things to consider when trying to control either one of these occurrences. Material considerations, part
geometry considerations, tooling considerations, and processing considerations all play a part.

5. Watch The Sharp Corners

Sharp corner are to be avoided at all costs. Sharp edges, such as corners of a square hole, will produce a part with high levels of molded-in stresses. These much of the time result in
weak points that lead to part failure and cracking. Adding radii to sharp corners will reduce the amount of molded-in stress. Radii redistributes the stress more evenly and facilitates the
flow of the material and ejection from the mold. Stresses rapidly build whenever the inside corner id less than 25% of the nominal wall thickness of the part.

​6. Structural Support

As a product designer you want to minimize the amount of material required to fill your part, while at the same time increasing its structural integrity. Thin walls need some sort of
support so that the walls don't warp or collapse. Ribs are commonly employed on injection molded parts in order to stiffen relatively thin parts. Ribs, bosses and other projections on
the piece part wall will greatly strengthen your part while, but if done incorrectly can contribute to other molding issues such as sink marks and non-fills.

7. Add Draft
Draft is the angling of otherwise vertical walls in order to prevent constant contact with the molding cavity during the mold opening. All vertical walls oriented normal to the direction
of mold pull will need to have draft ideally at 1 degree minimum. There are special consideration for ribs and bosses, and textured surfaces will need to add 1 degree per side for each
.001" depth of texture. Draft is an essential element to the part design process.
8. Secondary Operation or Molded In?
Sometimes you have inserts that need to be fixed inside your part. You need to consider whether they get molded in or they are presses or welded in after the molding has
commenced. With this, both options are viable and come down to the economics of the operation. Do you go for a higher priced tool that can accommodate inserts to be molded over,
or do you press them into the part after the fact. If you have a low production run, it might be worth considering a post molding operation. For long production runs, it might be more
beneficial to have the inserts molded in. It all depends on the customer's preference, the viability, and the project's budget.

9. Gating and Ejection

Gate location is the area where the material will be entering into and filling the cavity of the part. It is important to keep in mind where you intend to gate your part and possibly make
provision. Some questions to consider are: Am I allowed to have a gate mark where I am envisioning my gate? and Is this gate at a location where the material will flow from a thick
walled to a thin walled region of the part. You must also account for ejector pin marks that will most likely show up on the underside of your molded part. If ejector marks are not
allowed then that must be called out on your print so other ejection alternative can be considered.

10. Material Selection

​The material selection process can be as simple as an internet search for the material of an existing part already on the market, or as complex as identifying every single requirement
and material property from the ground up. The first step is to define the requirements needed for your particular application. From there it's important to narrow the choices b process
of elimination. Do you need it to be rigid, flexible, elastomeric etc? Is there a specific application? Medical? What specific property requirements are there? Sometimes the best thing to
do is to not reinvent the wheel and do a search history for similar commercial application s if possible, then call up the material supplier for recommendations.
PLASTICS PART DESIGN and MOULDABILITY

Injection moulding is popular manufacturing method because of its high-speed production capability. Performance of plastics part is limited by its properties which is not as strong (as
good) as metal. There are applications where the available properties of the plastics can be useful. The strength of plastics can be improved with reinforcement of glass fibre, mica, talk
etc.

Plastics generally have following characteristics,

Light weight - low density,

Low conductivity of heat and electricity - insulating properties,
Low hardness,
Lower strength than metals,
Ductile,
Dimensional stability- not as good as metal,

WALL THICKNESS

Solid shape moulding is not desired in injection moulding due to following reasons.

• Cooling time is proportional to square of wall thickness. Large cooling time for solid will defeat the economy of mass production. (poor conductor of heat)
• Thicker section shrink more than thinner section, thereby introduce differential shrinkage resulting in warpage or sink mark etc. (shrinkage characteristics of plastics and pvT
characteristics)

Therefore we have basic rule for plastic part design; as far as possible wall thickness should be uniform or constant through out the part. This wall thickness is called nominal wall
thickness.
If there is any solid section in the part, it should be made hollow by introducing core. This should ensure uniform wall thickness around the core.

What are the considerations for deciding wall thickness?

• It must be thick and stiff enough for the job. Wall thickness could be 0.5 to 5mm.
• It must also be thin enough to cool faster, resulting lower part weight and higher productivity.

Any variation in wall thickness should be kept as minimum as possible.

A plastic part with varying wall thickness will experience differing cooling rates and different shrinkage. In such case achieving close tolerance becomes very difficult and many times
impossible. Where wall thickness variation is essential, the transition between the two should be gradual.