Designing with Plastics

MFG 355
 Design Methodology
• Inspiration
• Concept
• Prototype
• Development
• Final product
 Layout or Drawing
• Sketch
• Drawing
• CAD
• Advantages and disadvantages to each
– Detail
– Complexity
– Time
– Communication of idea
– Visualization of problems
 Constraints
• Appearance
• Mechanical
• Environmental
• Safety, Codes and Standards
• Manufacturing Method/Design Rules
• Economics
 Material Choice
• Database – IDES (like in lab) or others
Multiple grades
– Multiple additives
– Multiple blends
– Improvements
 Material Choice
• Selection methodology
– Define the criteria for material selection
– Determine the advantages and disadvantages
of each polymer type
– Select polymers for special properties
– Rank the resins and make a preliminary
selection
• Computer-aided selection
ABS-acrylonitrile butadiene styrene
FP-fluoropolymers
Material Choice
HDPE-high density polyethylene
LCP-liquid crystal polymers
LDPE-low density polyethylene PI
PA 4,6-polyamide 4,6 PAI PEEK
High
PA 6/6,6-polyamide 6/6,6 TPI FP Performance
PAI-polyamide imide
PAR-polyarylate PPSU PVDF
LCP Polymers
PEI PPS
PBT-polybutylene terephthalate PES

nce
PC-polycarbonate PSF PPA
PE UHMW-ultrahigh mol. weight PE PAR PA-4,6

ma
PEEK-polyetheretherketone
PEI-polyether imide PPC PET
PES-polyethersulfome
r
erfo
PET-polyethylene terephthalate PBT
PC PA-6/6,6
PI-polyimide Mid-Range
PMMA-polymethyl methacrylate POM Polymers
st/P

POM-polyoxymethylene
PP-polypropylene
PPO PE-UHMW
Co

PPA-polyphtalamide
PPC-polyphthalate carbonate SMA ABS PMMA PP
PPO-polyphenylene oxide
PPS-polyphenylene sulfide
PS SAN
PPSU-polyphenylsulfone HDPE
PS-polystyrene
PSF-polysulfone Common
PVC-polyvinyl chloride PVC
PVDF-polyvinylidene fluoride LDPE Polymers
SAN styrene acrylonitrile
SMA-styrene maleic anhydride
TPI-thermoplastic polyimide Amorphous Semi-crystalline
 Material Selection Matrix
Properties

Property 1: Property 2: Property 3: Property 4:

WF= WF= WF= WF=

Value/ Value/ Value/ Value/ Total

Resins Rank Score Rank Score Rank Score Rank Score Score
 Material Selection
• Choosing material for a snow sled
 Material Selection Matrix
• Choosing material for a snow sled
Properties

Property 1: Property 2: Property 3: Property 4:

WF= WF= WF= WF=

Value/ Value/ Value/ Value/ Total
Resins Rank Score Rank Score Rank Score Rank Score Score

HDPE

LDPE

ABS

PC

PS

PP
Possible resins
 Material Selection Matrix
• Choosing material for a snow sled
Properties
Property Property 2: Property 3:
1:Toughness Abrasion Resist Surface Finish Property 4: Cost

WF= WF= WF= WF=

Value/ Value/ Value/ Value/ Total
Resins Rank Score Rank Score Rank Score Rank Score Score

HDPE

LDPE

ABS

PC

PS

Desired properties PP
 Material Selection Matrix
• Choosing material for a snow sled
Properties
Property Property 2: Property 3:
1:Toughness Abrasion Resist Surface Finish Property 4: Cost

WF= 5 WF= 5 WF= 3 WF= 4

Value/ Value/ Value/ Value/ Total
Resins Rank Score Rank Score Rank Score Rank Score Score

HDPE

LDPE

ABS

PC

PS

Weighting factor PP
(Higher is more
Important)
 Material Selection
Impact Toughness Guide
Resin Izod (ft-lb) Reasoning

Polyurethane (x-link) 25 High elongation and strength

Polycarbonate 16 High strength

SMC 7 Reinforced and toughened

ABS 6 Toughened with rubber

HDPE 3 High elongation, flexible

Increasing Toughness

Acetal 2 Can be toughened

Nylon 6/6 2 Can be toughened

PET 1 Can be alloyed

PP 1 Some crystallinity

LDPE 1 Low strength

Polystyrene 0.3 Pendent group

Acrylic 0.3 Short link, large pendent group

Phenolic, w/fiberglass 0.3 Crosslinked

Epoxy, unreinforced 0.2 Crosslinked

Crosslinked polyester 0.2 Crosslinked

 Material Selection Matrix
• Choosing material for a snow sled
Properties
Property Property 2: Property 3:
1:Toughness Abrasion Resist Surface Finish Property 4: Cost

WF= 5 WF= 5 WF= 3 WF= 4

Value/ Value/ Value/ Value/ Total
Resins Rank Score Rank Score Rank Score Rank Score Score

HDPE 4 3 1 5

LDPE 2 6 1 6

ABS 5 4 1 2

PC 6 2 1 1

PS 1 1 1 3

Values rank PP 3 5 1 4
from properties
(Higher is better)
 Material Selection Matrix
• Choosing material for a snow sled
Properties
Property Property 2: Property 3:
1:Toughness Abrasion Resist Surface Finish Property 4: Cost

WF= 5 WF= 5 WF= 3 WF= 4

Value/ Value/ Value/ Value/ Total
Resins Rank Score Rank Score Rank Score Rank Score Score

HDPE 4 20 2 10 1 3 5 20

LDPE 2 10 6 30 1 3 6 24

ABS 5 25 4 20 1 3 2 8

PC 6 30 3 15 1 3 1 4

Score = value x WF PS 1 5 1 5 1 3 3 12

PP 3 15 5 25 1 3 4 16
 Material Selection Matrix
• Choosing material for a snow sled
Properties
Property Property 2: Property 3:
1:Toughness Abrasion Resist Surface Finish Property 4: Cost

WF= 5 WF= 5 WF= 3 WF= 4

Value/ Value/ Value/ Value/ Total
Resins Rank Score Rank Score Rank Score Rank Score Score

HDPE 4 20 2 10 1 3 5 20 53

LDPE 2 10 6 30 1 3 6 24 67

ABS 5 25 4 20 1 3 2 8 56

PC 6 30 3 15 1 3 1 4 52

PS 1 5 1 5 1 3 3 12 25
Total Score
PP 3 15 5 25 1 3 4 16 59
 Material Selection Matrix
• Choosing material for a snow sled
Properties
Property Property 2: Property 3:
1:Toughness Abrasion Resist Surface Finish Property 4: Cost

WF= 5 WF= 5 WF= 3 WF= 4

Value/ Value/ Value/ Value/ Total
Resins Rank Score Rank Score Rank Score Rank Score Score

HDPE 4 20 2 10 1 3 5 20 53

LDPE 5 25 6 30 1 3 6 24 67 
ABS 2 10 4 20 1 3 2 8 56

PC 1 5 3 15 1 3 1 4 52

PS 6 30 1 5 1 3 3 12 25
Selecting the best
PP 3 15 5 25 1 3 4 16 59
 Prototyping
• Traditional
 Prototyping
• Rapid prototyping
– 3D printing
 Prototyping
• Rapid prototyping
– Stereolithography
 Prototyping
• Rapid prototyping
– Laminated object manufacturing (LOM)
 Prototyping
• Rapid prototyping
– Selective Laser Sintering (SLS)
 Prototyping
• Rapid prototyping
– Fused deposition modeling (FDM)
 Prototyping
• Rapid prototyping
– Fused deposition modeling (FDM)
 Process Selection
• Some parts are more suited for a particular
process
• Most parts can be modified and processed
through most of the different methods
• Some processes are incapable of producing
certain features
– Injection molding—hollow features
– Roto-molding—deep ribs
• We will be discussing all of the major processes
with their advantages, disadvantages and
molding requirements
 Process Selection Matrix
Features

Feature 1: Feature 2: Feature 3: Feature 4:

WF= WF= WF= WF=

Value/ Value/ Value/ Value/ Total
Processes Rank Score Rank Score Rank Score Rank Score Score
 Process Selection Matrix
• Process selection for a plastic pallet
 Process Selection Matrix
• Process selection for a plastic pallet

Features
Feature 1: Feature 2: Feature 3: Feature 4:

WF= WF= WF= WF=

Value/ Value/R Value/ Value/ Total
Processes Rank Score ank Score Rank Score Rank Score Score
Injection
molding
Thermo-
forming
Roto-
molding
Casting/
Possible Foaming

processes Extrusion
 Process Selection Matrix
• Process selection for a plastic pallet
Features
Feature 2: Net Feature 3: Short
Feature 1: Ribs shape/no assembly Cycle Time Feature 4: Size

WF= WF= WF= WF=

Value/ Value Value/ Value/ Total
Processes Rank Score /Rank Score Rank Score Rank Score Score
Injection
molding
Thermo-
forming
Roto-
molding
Casting/
Foaming

Extrusion

Features
 Process Selection Matrix
• Process selection for a plastic pallet
Features
Feature 2: Net Feature 3: Short
Feature 1: Ribs shape/no assembly Cycle Time Feature 4: Size
WF= 4 WF= 3 WF= 5 WF= 6
Value/ Value/ Value/ Value/ Total
Processes Rank Score Rank Score Rank Score Rank Score Score
Injection
molding
Thermo-
forming
Roto-
molding
Casting/
Foaming

Weighting Factor Extrusion

(higher is more
Important)
 Process Selection Matrix
• Process selection for a plastic pallet
Features
Feature 2: Net Feature 3: Short
Feature 1: Ribs shape/no assembly Cycle Time Feature 4: Size

WF= 4 WF= 3 WF= 5 WF= 6

Value/ Value/ Value/ Value/ Total
Processes Rank Score Rank Score Rank Score Rank Score Score
Injection
molding 5 20 3 9 5 25 2 12
Thermo-
forming 1 4 2 6 2 10 4 24
Roto-
molding 2 8 5 15 1 5 5 30
Score–assessment Casting/
Foaming 4 16 4 12 3 15 3 18
(higher is better)
Extrusion 3 12 1 3 4 20 1 6
 Process Selection Matrix
• Process selection for a plastic pallet
Features
Feature 2: Net Feature 3: Short
Feature 1: Ribs shape/no assembly Cycle Time Feature 4: Size

WF= 4 WF= 3 WF= 5 WF= 6

Value/ Value/ Value/ Value/ Total
Processes Rank Score Rank Score Rank Score Rank Score Score
Injection
molding 5 20 3 9 5 25 2 12 66
Thermo-
forming 1 4 2 6 2 10 4 24 44
Roto-
molding 2 8 5 15 1 5 5 30 58
Total score Casting/
Foaming 4 16 4 12 3 15 3 18 61
(higher is better)
Extrusion 3 12 1 3 4 20 1 6 41
 Process Selection Matrix
• Process selection for a plastic pallet
Features
Feature 2: Net Feature 3: Short
Feature 1: Ribs shape/no assembly Cycle Time Feature 4: Size

WF= 4 WF= 3 WF= 5 WF= 6

Value/ Value/ Value/ Value/ Total
Processes Rank Score Rank Score Rank Score Rank Score Score
Injection
molding 5 20 3 9 5 25 2 12 66
Thermo-
forming 1 4 2 6 2 10 4 24 44
Roto-
molding 2 8 5 15 1 5 5 30 58
The best Casting/
Foaming 4 16 4 12 3 15 3 18 61

Extrusion 3 12 1 3 4 20 1 6 41
 3M Comply Product
Covered with adhesive

Plastic Sheet (PE)

Embossed Sheet (ribs connecting to edges)

Graphic film applied

Depressions filled with glass spheres

Separated graphic product

Multiply embossed sheet creating ridges and lands

Separated plastic sheet

 Avery-Dennison EZ Film Adhesive added
Plastic Sheet (PE)

Polyurethane printed cured forms (array)

Graphic film applied

Polyurethane forms pressed into the PE sheet

(thereby forming depressions and embossing the sheet)

Separated graphic product

PE sheet embossed with ridges and lands

Separated embossed PE sheet

Thank You