Professional Documents
Culture Documents
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? What loads will it experience in use? In
addition to functional and structural issues, processing issues play a large role in the design of an injection 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. Adhering to some basic rules of injection 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 minimizing molding problems. As a part is
developed, always keep in mind how the part is molded and what you can do to minimize 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) Gates
(i) Common Gates
(j) Gate Location
(k) Wall Thickness
(l) Draft
(m) Sink Marks
(n) Textures
(o) Parting Lines
(p) Common Molding Defects
Injection
Molding
Machine:
Injection molding machines, also known as presses, consist of a material hopper, an injection ram
or screw-type plunger, and a heating unit. Molds are clamped to the platen of the molding
machine, where plastic is injected into the mold through the sprue orifice. Presses are rated by
tonnage, which is the calculation of the amount of clamping force that the machine can exert. This
force keeps the mold closed during the injection molding process. Tonnage can vary from less
than 5 tons to 6,000 tons, although the higher tonnage presses are rarely used. The total clamp
force needed is determined by the projected area of the custom part being molded. This projected
area is multiplied by a clamp force of from 2 to 8 tons for each square inch of the projected areas.
As a rule of thumb, 4 or 5 tons/in can be used for most products. If the plastic material is very stiff,
it will require more injection pressure to fill the mold, thus more clamp tonnage is needed to hold
the mold closed. The required force can also be determined by the material used and the size of
the part with larger plastic parts requiring higher clamping force.
Mold:
The mold or die refers to the tooling used to produce plastic parts in molding. Traditionally
injection molds have been expensive to manufacture and were only used in high-volume
production applications where thousands of parts were produced. Molds are typically constructed
from hardened steel, pre-hardened steel, aluminum, and/or beryllium-copper alloy. The choice of
material to build a mold from is primarily one of economics. Steel 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. Pre-hardened steel molds are less wear resistant and are
primarilly used for lower volume requirements or larger components. The hardness of the prehardened steel measures typically 38-45 on the Rockwell-C scale. Hardened steel molds are heat
treated after machining, making them superior in terms of wear resistance and lifespan. Typical
hardness ranges between 50 and 60 Rockwell-C (HRC).
Aluminum molds cost substantially less than steel molds, and when higher grade aluminum such
as QC-7 and QC-10 aircraft aluminum is used and machined with modern computerized
equipment, they can be economical for molding hundreds of thousands of parts. Aluminum molds
also offer quick turnaround and faster cycles because of better heat dissipation. They can also be
coated for wear resistance to fiberglass reinforced materials. Beryllium copper is used in areas of
the mold which require fast heat removal or areas that see the most shear heat generated.
Co-injection(sandwich)molding
Injection-compression molding
Microinjection molding
Microcellular molding
Rheomolding
Thin-wall molding
Rubber injection
As the material cools and the molecular bonds re-link the resin into its rigid form, these stresses are in effect locked
into the part. Part stresses can cause warpage, sink marks, cracking, premature failure and other problems.
While some stresses in an injection molded part are to be expected, you should design your parts with as much
consideration for stress reduction as possible. Some ways to do this are by adding smooth transitions between
features and using rounds and fillets in possible high stress areas.
Flow distribution for certain designs that require simultaneous flow distribution
across a wide front
Automatically Trimmed
Gates
These type of gates incorporate features in the tool to break or shear the gates when the
tool opens to eject the part. Automatically trimmed gates are used for several reasons:
rather than on the parting line and are ideal for round or conical shapes where uniform flow is necessary. This gate
leaves a small raised nub on the surface of the part. Hot tip gates are only used with hot runner molding systems. This
means that, unlike cold runner systems, the plastic is ejected into the mold through a heated nozzle and then cooled to
the proper thickness and shape in the mold.
The Direct or Sprue Gate 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. This gate leaves a large scar on the part at
the point of contact.
Place gates at the heaviest cross section to allow for part packing and minimize voids & sink.
Minimize obstructions in the flow path by placing gates away from cores & pins.
Be sure that stress from the gate is in an area that will not affect part function or aesthetics.
o
If 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
Gate should minimize flow path length to avoid cosmetic flow marks.
In some cases, it may be necessary to add a second gate to properly fill the parts.
If filling problems occur with thin walled parts, add flow channels or make wall thickness adjustments to correct
the flow.
Gates vary in size and shape depending upon the type of plastic being molded and the size of the part. Large parts will
require larger gates to provide a bigger flow of resin to shorten the mold time. Small gates have a better appearance
but take longer time to mold or may need to have higher pressure to fill correctly.
Choosing the proper wall thickness for your part can have drastic effects on the cost and production
speed of manufacturing. While there are no wall thickness restrictions, the goal is usually to choose
the thinnest wall possible. Thinner walls use less material which reduces cost and take less time to
cool, reducing cycle time.
The minimum wall thickness that can be used depends on the size and geometry of the part,
structural requirements, and flow behavior of the resin. The wall thicknesses of an injection molded
part generally range from 2mm 4mm (0.080 0.160). Thin wall injection molding can produce
walls as thin as 0.5mm (0.020). The chart below shows recommended wall thicknesses for common
injection molding resins.
Uniform Wall
Thickness:
Thick 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. As the
thick section cools, it shrinks around the already solid thinner section. This causes warping, twisting or
cracking to occur where the two sections meet. To avoid this problem, try to design with completely
uniform walls throughout the part. When uniform walls are not possible, then the change in thickness
should be as gradual as possible. Wall thickness variations should not exceed 10% in high mold
shrinkage plastics. Thickness transitions should be made gradually, on the order of 3 to 1. This
If your part is so complex that you need variations on your wall thickness, look for an alternative. You
may want to use design features such as coring or using ribs. At the very least, try not to make the
transitions between thicker and thinner sections too abrupt. Try using a gradual transition or
chamfered corners to minimize the dramatic change in pressures inside the mold.
used to hide finger prints and improve the grip for the end user. Texture can also be used to reduce part wear from
friction.
A wide variety of textures are available for injection molded parts such as:
Natural/Exotic
Matte Finishes
Multi-Gloss Patterns
Fusions
Graphics
Leather Grains/Hides
When applying a texture to a part, the CAD drawing must be adjusted to accommodate for this surface variance. If the
texture is on a surface that is perpendicular or angled away from the mold opening then no draft changes are
necessary. If 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 ejection. Different textures have different impacts on the
molded part. The rule-of-thumb when designing for texture is to have 1.5 degrees of draft for each 0.001 of texture
finish depth.
Molding
Defects
Alternative
Name
Blister
Blistering
Burn marks
Air Burn/Gas
Burn
Color streaks
(US)
Descriptions
Causes
Delamination
Flash
Burrs
Embedded
contaminates
Embedded
particulates
Flow marks
Flow lines
Jetting
Poor tool design, gate position or runner. Injection speed set too
high.
Polymer
degradation
Sink marks
Localized depression
(In thicker zones)
Holding time/pressure too low, cooling time too short, with sprueless
hot runners this can also be caused by the gate temperature being
set too high
Partial part
Short shot
Splay marks
Stringiness
Non-Fill/Short
Mold
Splash
Mark/Silver
Streaks
Stringing
Voids
Weld line
Knit Line/Meld
Line
Warping
Twisting Part
Distorted part
Cooling 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)
Keep these factors in mind when designing your injection molded part, and remember that it is easier to avoid
problems in the beginning than change your design down the line.
Term
Definition
Boss
Refers to the round protrusions on plastic parts and molds (#2 in Figure 1 below)
Cavity
Refers to the upper half of the injection mold usually the show surface of the
finished product but is mainly concave
Core
Refers to the side of the tool where the plastic part is injected from; also known as
the bottom half of the tool
Core Outs
Refers to the portion of a part that is gutted out in order to achieve uniform wall
thickness. This portion of the part has no end use function other than lightening the
part and reducing warp
Draft
Refers to portion of injection molding part that has some taper to make it easier to
remove from the mold. Generally all plastic components should be designed with
draft where possible
Gate
Refers to where the plastic enters into the cavity of the mold. The two types of
gates are as follows:
1. Automatically Trimmed Gates: Gates that incorporate features in the tool to
break or shear the gate as the molding tool is opened to eject the part
2. Manually Trimmed Gates: Gates that require an operator to separate parts
from runners during a secondary operation
Gibbs
Area of the custom injection mold that holds the slide down so the cam can actuate
it
:: Case Study
Quickparts offers three options for CNC Machining including Manufactured Plastic
Prototypes (MPP), CNC Machined Parts and QuickCutCNC. Each option targets a
different requirement price, speed or precision. The chart below shows how these
different product lines compare to each other based on several aspects.
Max
Dimensions
Material
Options
Manufactured Plastic
Prototypes (MPP)
Fit & form testing, durable
functional parts, and
conceptual models
12" x 12" x 3" (Instant
Quoting)
ABS (natural & black)
& Acrylic clear
Finish
Standard, Polished
Lead Time
8 - 11 business days
Tolerance
+/- 0.010"
+/- 0.005"
+/- 0.005"
Quoting
Options
Instant Online
Capabilities
Application
QuickCutCNC
3 Axis Milling
If price is your driver, then the MPP option is best. MPP offers three plastic materials to
choose from and parts are received in approximately 8-11 business days. Instant online
quoting is available for parts up to 12 in size; however this process can accommodate part
sizes much, much larger.
If speed is the priority for your machining project then QuickCutCNC, the newest addition to
the Quickparts family, is your best option. QuickCutCNC boasts a 3-5 day lead time and
offers over 30 different plastic and metal materials to choose from including specialized
PEEK and Ultem materials. Design guidelines are used for this process in order to
produce parts with such a fast lead time.
If a high level of precision is required, the CNC machining option is the right choice. This
process is the most comprehensive machining option available regarding capabilities, finish
options, material options and part dimensions. Lead times vary based on project
requirements, but can be as quick as 6-8 days depending on geometry.