Plastic Part Design

Plastics One Injection Molding

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) Proper 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 effective. 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 have to be "maintain uniform
wall thickness". Here are some examples of problems associated with part designs that feature
non-uniform wall thicknesses:

Sink marks due to uneven shrinkage Stress due to uneven shrinkage

Sink marks result from a wall yielding A part with non-uniform wall thickness will cool unevenly,
to the still shrinking interior mass. resulting in high molded-in stress.

Voids due to uneven shrinkage Warpage due to uneven shrinkage

The already cooled section will not yield to Concentrated stress at the junction of high & low shrinkage
the shrinking action of the cooling interior mass areas may cause a pa
causing voids in the thick portion of the part.

Draft
Plastics One Injection Molding

Plastic parts are always designed with a taper or draft in the direction of mold movement to allow
part ejection or removal from the mold. Since plastics shrink when cooled, it is common for parts
to shrink (or grip tightly) to cores. A 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.
Without proper draft, plastic parts may be difficult to remove from the mold. A draft angle of 1/2
degrees is regarded as minimum for most applications. Draft angles of 1 1/2 to 2 degrees per
side are considered normal for plastic injection molding.
 Plastics One Injection Molding

Many times the stiffness of a part must increase because of the load applied to the part design.
One of the easiest ways to cure this problem is change the part geometry by adding ribs. The use
of ribs is a practical way and economical means of increasing the structural strength of a part. But
there are guidelines that govern adding ribs without causing sink marks or surface blemishes to
your parts.

1) Rib thickness should be less than wall thickness. A rib thickness of 60% to 80% of nominal wall
thickness is recommended.

2) To increase stiffness increase the number of ribs or "gusset plates", another feature designed
to strengthen the plastic part.

Height: max. height of three times nominal

wall thickness of part

Spacing: minimum of two times nominal wall

thickness of part between ribs

3) For a given stiffness, it is better to increase the number of ribs, not the height.

4) For thick ribs "core out" the rib from the back. This creates a hollow space underneath the part
and maintains a uniform wall thickness.
 Holes
Plastics One Injection Molding

Holes are easy to produce in molded parts. Core pins that protrude into the mold cavity make the
holes when the part is molded. Through holes in the molded parts are easier to produce than
blind holes, which do not go all the way through a part. Blind holes are made by core pins
supported on one end only. The pins can be deflected and pushed off center by the pressures of
the molten plastic material during the molding process. A good rule of thumb: the depth of the
blind hole should be about twice the diameter of core pins up to 3/16", and up to four times the
diameter of core pins over 3/16". The guidelines for blind and through holes are seen below.

Blind Hole (shown with draft)

L= 2D for Diameters Less than 3/16" dia. core pins

L= 4D for Diameters More than 3/16" dia. core pins

Through Hole (shown with draft)

L= 4D for D <3/16" dia. core pins

L= 6D for D >3/16" dia. core pins

There are definite rules for the placement of cored holes in a molded part. If 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.

T= wall thickness of part

D= diameter of hole

As 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. This
same rule applies between holes - at least two part thicknesses or one hole diameter should be
specified.
Holes (part 2)

Plastics One Injection Molding

As easy as it is to make holes in molded parts it does not come

without some concerns for the strength of the part. For every
cored or molded hole there will be a weld line. The weld lines are
caused by the flow of the melted plastic around the core pins.
These weld lines are not as strong as the surrounding plastic
material, and also may detract from the overall appearance of the
molded part. The part designer should consider these points when
designing holes in a molded part.

The coring of holes is easy when the axis is parallel to the parting
line. But when
holes and other features run perpendicular to the parting line then
retractable cores
(or cams) are required. Split pins and cores (called passing steel
shutoffs) can be used
to create some of the features. The designer needs to be aware of
the problems of
side action cores and the added expenses associated with these
types of molds. With a
little understanding of how the mold opens and where the parting
line will exist, these
costly features can be modified. Rule 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
Plastics One Injection Molding

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

Rule of thumb: the wall thickness around a boss design feature (t) should be 60% of the nominal
part thickness (T) if that thickness is less than 1/8". If the nominal part thickness is greater than
1/8" the boss wall thickness should be 40% of the nominal wall.
 Boss diameter, wall thickness, and height design parameters. While
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 2 1/2 times the diameter of the hole in
the boss.

Please observe the "60/40" rule (see above) for the wall thickness at the bottom of the boss.

Radii
Plastics One Injection Molding

In the design of injection molded parts, sharp corners should be avoided. Sharp
corners act as stress risers or concentrators, reducing part strength and causing
premature failures. Sharp corners may also effect plastic flow, producing parts with
objectionable surface flow patterns.

Corners
The inside radius should be at least
Bosses & Ribs half the part wall thickness
Nominal radius should be one quarter of
the nominal part thickness, with a minimum
radius of .015 (i.e. .100 wall, 025r)

The outside radius should equal

the inside radius plus the part
T= wall thickness of part Radius -T thickness (i.e. .100 wall and
inside radius of .050 equals
outside radius of .150)

Insert Molding Tips

Another problem concerning high stress occurs with molded-in inserts. The plastic melt heats the
metal of the inserts. During the cooling stage of injection molding, the plastic part cools, but the
plastic boss surrounding the metal insert is reheated by the heat from the insert. This allows the
plastic to continue to shrink around the insert, causing excessive hoop stress* that will eventually
cause the boss to crack. The 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.

Replacing Metal with Plastics

 Plastics One Injection Molding

There are numerous reasons why replacing metal parts with plastic makes sense. Plastics One,
Inc. has worked with many companies on metal-to-plastic conversions. Here's why plastic may be
the best option for your parts.

1. DECREASE PIECE PART PRICES

A penny saved is a penny earned. After 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 This cost savings is realized because the injection 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.

2. ELIMINATE TIME-CONSUMING AND COSTLY SECONDARY OPERATIONS

Eliminating secondary operations further reduces costs. Plastic material can be colored with color
concentrates before molding - eliminating secondary painting operations. Injection molds can be
textured or given various levels of polished surfaces before molding. The costly assembly of
several metal stampings or castings fastened together can often be replaced by a single injection
molded part incorporating the features of the total assembly. If multiple assemblies are required,
the plastic parts can have snap-together features to eliminate any fasteners. Eliminating sub-
assembly tooling or fixtures by using injection molded parts can quicken delivery in new product
development programs.

3. REDUCE PRODUCT WEIGHT AND IMPROVE USER EASE

One primary advantage of using plastics instead of metals is weight reduction Reducing product
weight with plastics gives you more parts per pound of material, significantly reduces shipping
costs and improves the end-user's physical ease in utilizing the product A comparison of the
specific gravity values of metals to plastics is shown in the following table:

METALS PLASTICS
Aluminum 2.5 to 2.8 Polycarbonate 1.2 to 1.4
Brass 8.4 to 8.7 Nylon (most types) 1.2 to 1.7
Copper 8.8 Polyethylene .92 to .95
Zinc 6.9 to 7.2 Polypropylene .90 to 1.04
Steels 7.7 to 7.83 ABS 1.02 to 1.4

4. GAIN GREATER PRODUCT STRUCTURAL STRENGTH

That third little pig really knew how to choose the right materials to build a strong house.
Choosing plastic over metal gives you products which are light-weight, easier to use and yet
possess increased structural strength. Plastic parts can be stronger than metal parts through the
use of engineering grade materials. In 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.

5. INCREASE YOUR PRODUCT DESIGN OPTIONS

Don't let the design limitations of metals trap you between a rock and a hard place. Increase your
design options and requirements and still keep costs down. The area of greatest difference
between metals and plastics is plastics' ease in producing complex shapes. The costly assembly
of several metal stampings or castings fastened together can often be

Plastics One Injection Molding

replaced by a single injection molded part incorporating the features of the total assembly. If
multiple assemblies are required, the plastic parts can have snap-together features to eliminate
any fasteners. Injection molded parts can shorten the time to the market place in new product
development programs because of elimination of sub-assembly tooling or fixtures. If heavy metal
shakes, rattles and rolls, then plastic twists and shouts. Plastics are easily processed into
complex shapes that would be impossible for metal because plastic materials have non-
Newtonian flow behavior. This means that the viscosity (resistance to flow) will decrease when
the flow rate increases. The flow rate is increased by increasing the injection pressures. The
standard injection molding pressures are 20,000 to 30,000 Psi. This 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.

6. SAVE DOLLARS BY RE-USING MATERIALS

Any way you look at it, recycling makes sense. Re-using materials by adding regrind (ground up
runners and scrap parts) to virgin materials generates even more cost savings. Plastic materials
fall into two basic types of process groups: Thermoset and Thermoplastic. Thermoset (often
called compression molding) is like working with epoxy. Once the material has been heated and
formed in a mold, it is set. The material cannot again be processed; it is literally a reaction by
temperature or thermally set. Examples of thermoset materials are Alkyd, Polyesters, Melamine
and Phenolic. Most injection molding plastics are thermoplastics; that is they can be reprocessed.
Thermoplastics fall into two distinctive molecular groups: amorphous and crystalline. Amorphous
materials when processed act like honey; that is they never really melt, they just soften and are
formed under pressure. Crystalline materials act like solder or ice. They have a specific melt
temperature and remain a solid until this temperature is reached. After the melt temperature is
achieved, the materials flow very easily with very low viscosities. When the material is cooled to a
temperature below the melt temperature, the material hardens to a solid form.

Amorphous Materials Crystalline Materials

Acrylic Nylon
ABS Polypropylene
Polystyrene Acteal
PVC Polyester
Polycarbonate Polyethylene
Comparison
Characteristics:
Shrinkage .004 - .012/in/in .012 - .025/in/in
Ease of flow relatively stiff flowing easy above melting
Dimensional control of parts easier to maintain close temperature more difficult to
dimensional tolerances maintain close dimensional
control

7. INCREASE PRODUCT LIFE

The Tin Man needed more than a brain to last - he needed an endless supply of oil as well.
Replace the environmental vulnerability of metals with the durability and longevity of
plastics. Most plastic materials have greater chemical resistance than most metals. Plastics
do not rust or oxidize as metals do and most are not affected, as are metals, by acids or
base compounds.

Design Guidelines for Metal to Plastic Conversions

Plastics One Injection Molding

There are several common mistakes made when replacing a metal product with a plastic
molded part. The new part design must adhere to specific material and molding process
guidelines. Several of the general guidelines are shown below:

See guidelines for uniform wall thickness when coring out sections

See Draft section for design specifications

Plastics One Injection Molding

Since 1949, Plastics One has specialized in the custom design, tooling, and injection insert
molding of products used in the medical, telecommunications, aerospace and consumer products
industries. Our Engineering and Tooling divisions are staffed by designers and mold makers with
the knowledge and computer-aided design experience to create the exact part for your needs. As
molders, we specialize in custom injection molding and insert molding using a wide variety of
engineering polymers, from thermoplastic elastomers to reinforced or filled resins. Shot sizes
range from 1/10th of a gram up to 80 ounces. In addition, we offer hot stamping, ultrasonic
welding, and packaging services for your convenience.

We invite you to visit our manufacturing plant.

You'll see first-hand why our "Success is in the Details."

Custom Injection Molding to Your Specifications

Our Custom Injection Molding Division specializes in the custom

design, tooling and injection/insert molding of products used in the
medical, telecommunications, aerospace and consumer products
industries. Our Engineering and Tooling divisions are staffed by
designers and mold makers with the knowledge and computer-aided
design experience to create the exact part for your needs.

As molders, we specialize in custom injection molding and insert

molding using a wide variety of engineering polymers - from
thermoplastic elastomers to reinforced or filled resins. Shot sizes range
from 1/10 of a gram up to 80 ounces. In addition, we offer hot
stamping ultrasonic welding and packaging services for your
convenience.

Plastics One of Roanoke, Virginia has grown to be recognized as a

leader in the custom injection molding field. Specializing in engineered
resins, small to medium size runs and detailed insert molding, the
company boasts an in-house design department utilizing the most
advanced three dimensional software, a fully equipped mold making
shop and the latest injection molding technology. We include here our
Design Guide, which is designed to be an informative, easy to follow
reference guide that we hope you go back to again and again.

We offer:

• One of the most sophisticated tool rooms in the mid-Atlantic.

• Extensive prototyping capabilities.
• Quick turn-around on tooling/parts quotations.
 • State of the art three-dimensional equipment allows our team of
specialists to conceive and analyze parts and systems before
physical prototypes are made.

Our RAM Optical Measurement System offers the ultimate in

mechanical, optical, video and computer technology allowing both
quantitative and qualitative analysis. In-house tooling utilizing the
most advanced machining equipment available, generates quality,
time controls and a cost effectiveness.

The advantages in metal to plastic conversion is cost savings with

improved product quality. We will provide you with input and
prototyping services to consider the advantages to replacing metal
casting with injection or insert molding. We also utilize a Lean
Manufacturing concept in our processes to allow the best quality
possible to our customers.

METAL TO PLASTIC CONVERSION

• Decrease Piece Part Prices
• Eliminate Time-Consuming and Costly Secondary Operations
• Reduce Product Weight and Improve User Ease
• Gain Greater Product Structural Strength
• Increase Your Product Design Options
• Save Dollars by Re-Using Materials
• Increase Product Life

The single most important benefit in metal to plastic conversion is cost

savings with improved product quality. Let's consider the advantages
to replacing metal casting with injection or insert molding.
1. Decrease Piece Part Prices (Top)
A penny saved is a penny earned. After 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. This cost savings is realized because the injection 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.

2.Eliminate Time-Consuming and Costly Secondary Operations

(Top)
Eliminating secondary operations further reduces costs. Plastic
material can be colored with color concentrates before molding -
eliminating secondary painting operations. Injection molds can be
textured or given various levels of polished surfaces before molding.
The costly assembly of several metal stampings or castings fastened
together can often be replaced by a single injection molded part
incorporating the features of the total assembly. If multiple assemblies
are required, the plastic parts can have snap-together features to
eliminate any fasteners. Eliminating sub-assembly tooling or fixtures
by using injection molded parts can quicken delivery in new product
development programs.

3. Reduce Product Weight and Improve User Ease (Top)

One primary advantage of using plastics instead of metals is weight
reduction. Reducing product weight with plastics gives you more parts
per pound of material, significantly reduces shipping costs and
improves the end-user's physical ease in utilizing the product.
A comparison of the specific gravity values of metals to plastics is
shown in the following table:

METALS PLASTICS
Aluminum 2.5 to 2.8 Polycarbonate 1.2 to 1.4
Brass 8.4 to 8.7 Nylon(most types) 1.2 to 1.7
Copper 8.8 Polyethylene .92 to .95
Zinc 6.9 to 7.2 Polypropylene .90 to 1.04
Steels 7.7 to 7.83 ABS 1.02 to 1.4

4. Gain Greater Product Structural Strength (Top)

That third little pig really knew how to choose the right materials to
build a strong house. Choosing plastic over metal gives you products
which are light-weight, easier to use and yet possess increased
structural strength. Plastic parts can be stronger than metal parts
through the use of engineering grade materials. In 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.

5. Increase Your Product Design Options (Top)

Don't let the design limitations of metals trap you between a rock and
a hard place. Increase your design options and requirements and still
keep costs down. The area of greatest difference between metals and
plastics is plastics' ease in producing complex shapes. The costly
assembly of several metal stampings or castings fastened together can
often be replaced by a single injection molded part incorporating the
features of the total assembly. If multiple assemblies are required, the
plastic parts can have snap-together features to eliminate any
fasteners. Injection molded parts can shorten the time to the market
place in new product development programs because of elimination of
sub-assembly tooling or fixtures.
If heavy metal shakes, rattles and rolls, then plastic twists and shouts.
Plastics are easily processed into complex shapes that would be
impossible for metal because plastic materials have non-Newtonian
flow behavior. This means that the viscosity (resistance to flow) will
decrease when the flow rate increases. The flow rate is increased by
increasing the injection pressures. The standard injection molding
pressures are 20,000 to 30,000 Psi. This 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.

6. Save Dollars by Re-Using Materials (Top)

Any way you look at it, recycling makes sense. Re-using materials by
adding regrind (ground up runners and scrap parts) to virgin materials
generates even more cost savings.
Plastic materials fall into two basic types of process groups: Thermoset
and Thermoplastic. Thermoset (often called compression molding) is
like working with epoxy. Once the material has been heated and
formed in a mold, it is set. The material cannot again be processed; it
is literally a reaction by temperature or thermally set. Examples of
thermoset materials are Alkyd, Polyesters, Melamine and Phenolic.
Most injection molding plastics are thermoplastics; that is they can be
reprocessed. Thermoplastics fall into two distinctive molecular groups:
amorphous and crystalline. Amorphous materials when processed act
like honey; that is they never really melt, they just soften and are
formed under pressure. Crystalline materials act like solder or ice.
They have a specific melt temperature and remain a solid until this
temperature is reached. After the melt temperature is achieved, the
materials flow very easily with very low viscosities. When the material
is cooled to a temperature below the melt temperature, the material
hardens to a solid form.

Amorphous Materials Crystalline Materials

Acrylic Nylon
ABS Polypropylene
Polystyrene Acteal
PVC Polyester
Polycarbonate Polyethylene

Comparison Characteristics:

Amorphous Crystalline
Materials Materials
Shrinkage .004 - .012 in/in .012 - .025/in/in
relatively stiff easy above melting
Ease of flow
flowing temperature
Dimensional easier to more difficult to
control maintain maintain

7. Increase Product Life (Top)

The Tin Man needed more than a brain to last - he needed an endless
supply of oil as well. Replace the environmental vulnerability of metals
with the durability and longevity of plastics. Most plastic materials
have greater chemical resistance than most metals. Plastics do not
rust or oxidize as metals do and most are not affected, as are metals,
by acids or base compounds.

Since 1949, Plastics One has specialized in the custom design, tooling,
and injection and insert molding of products used in the medical,
telecommunications, aerospace and consumer products industries. Our
Engineering and Tooling divisions are staffed by designers and mold
makers with the knowledge and computer-aided design experience to
create the exact part for your needs. As molders, we specialize in
custom injection molding and insert molding using a wide variety of
engineering polymers, from thermoplastic elastomers to reinforced or
filled resins. Shot sizes include 1/10 of a gram up to 79 ounces. In
addition, we offer hot stamping, ultrasonic welding, and packaging
services for your convenience.