PLASTICS

PRODUCT DESIGN

PART DESIGN
MAIN FACTORS
1.END USE
2.MATERIAL PROPERY
3.MANUFACTURING PROCESS

PRIME CONSIDERATION OF A PART DESIGN

BASED ON END USE
i. SHAPE SIMPLE/COMPLEX, HOLLOW/
SOLID,FLAT/ROUND
ii. SIZE LARGE / SMALL , THICK / THIN &
iii. PART FEATURES

PART FEATURES
DETAILS TO BE CONSIDERED IN A PART
1. WALL THICKNESS
2. CORNERS
3. RIBS
4. BOSSES
5. WELD LINES
6. DRAFT
7. PARTING PLANE
8. UNDERCUT
9. INSERTS
10.TOLERANCES
11.LOAD & STRENGTH
12.HINGES & SNAP FIT
13.THREAD

WALL THICKNESS
PLASTIC MATERIAL PROPERTIES GOVERNING
WALL THICKNESS OF PLASTICS PART
1. MATERIAL STRUCTURE PARTLY AMOURPHOS,
PARTLY CRYSTALLINE & VISCOSITY.
2. PROCESS THE NATURE OF PLASTIC PRODUCT
MANUFACTURING IS MATERIAL ADDITION.
3. THERMAL CONDUCTION PLASTICS IS BAD
CONDUCTOR OF HEAT , HENCE SOLIDIFICATION
PROCESS VARIES WITH THICKNESS.
4. THERMAL EXPANSION / SHRINKAGE
ABOVE FACTORS INDICATE , WALL THICKNESS SHOULD
BE UNIFORM AND THIN.

PLASTICS PRODUCT DESIGN

WALL THICKNESS
WALL THICKNESS SHOULD BE AS UNIFORM AS POSSIBLE
TO ELIMINATE INTERNAL STRESSES, PART DISTORTION,
AND CRACKING.

WALL THICKNESS

PLASTICS PRODUCT DESIGN

WALL THICKNESS

If two different wall

thickness is join , blending
should be Gradual

PLASTICS PRODUCT DESIGN

PLASTICS PRODUCT DESIGN

WALL THICKNESS

PLASTICS PRODUCT DESIGN

WALL THICKNESS
GOOD DESIGN

BAD DESIGN

UNIFORM WALL
THICKNESS IS DESIRABLE

PLASTICS PRODUCT DESIGN

CORNERS
GOOD DESIGN

BAD DESIGN

SHARP CORNERS
SHOULD BE AVOIDED

RIBS
PURPOSE IT HAS TWO PURPOSE
A)
B)

TO IMPROVE MELT FLOW IN THE SECTION

TO INCREASE FLEXURAL STIFFNESS

If a part has wall thickness W, and thickness W is added as

follows
Case (a) Parallel Along thickness &
Case (b) perpendicular to wall , then
Comparing Case (a) and Case (b)
Section Modulus - is proportional to Square of thickness.
Weight
- is proportional to thickness
Cooling Time
- is proportional to Square of thickness
Increasing Stiffness Reduce
Deflection

Reduce Creep Strain

Natural Frequency
Impact Resistance

PLASTICS PRODUCT DESIGN

RIBS -

The Rib design and

proportions used in most
thermoplastic materials

Note : If thickness C is
more than 0.8A, Sink mark
will appear.

PLASTICS PRODUCT DESIGN

RIBS -

A uniform wall thickness

can be maintained in a
rib if it is hollowed or
cored out from the back

PLASTICS PRODUCT DESIGN

RIBS -

A Rib should be located in

the corner or side of a
moled part. This will
lower the mold cost and
allow easier filling of the
plastic part

PLASTICS PRODUCT DESIGN

RIBS -

IF THE RIB IS TO BE EXTREMELY

THIN AND AWAY FROM SIDES OF
PART, FILLING MAY BE HELPED BY
ADDING INTERMITTENT HEAVY
SECTION ON WHICH VENT PIN CAN
BE PLACED.

BOSSES
It is protruding studs on a part that assist in
assembly of the plastic parts and also bear
stress and strain therein.

PLASTICS PRODUCT DESIGN

BOSSES

Design and
proportions of boss
at a wall, it is used
in most
thermoplastic
materials

PLASTICS PRODUCT DESIGN

BOSSES
Design and
proportions of boss
away from a wall, it
is used in most
thermoplastic
materials

Note : If thickness C
is more than 0.8

PLASTICS PRODUCT DESIGN

BOSSES

Ribs on the side of long

bosses will aid in filling
them

PLASTICS PRODUCT DESIGN

BOSSES

Recommended proportions
for Boss on the outside of a
moulded part
B = A or 2A max.

PLASTICS PRODUCT DESIGN

Gusset Design
RIM DESIGN
It is an undercut in the
part and is used to give
added strength and
support.
GUSSETS
These are supporting
arrangements for an edge.
For additional support, two
or more gussets do the job
better than increasing
height or width .

PLASTICS PRODUCT DESIGN

DRAFT

TAPER IS PROVIDED IN A MOLD WALL TO

FACILITATE EASY EJECTION. Also HELPS IN
STACKING

PLASTICS PRODUCT DESIGN

MOULDED HOLE i)

ii)

Holes should be Parallel to Draw of mold

as it opens. Oblique angle hole are
expensive to manufacture.

Strength of PIN forming the moulded hole

is influenced by ratio of Diameter to
Length called Slenderness Ratio.

PLASTICS PRODUCT DESIGN

MOULDED HOLE -

PLASTICS PRODUCT DESIGN

MOULDED HOLE
HOLES OF VERY SMALL DIAMETER IN CASE OF COMPRESSION
MOLDING

PLASTICS PRODUCT DESIGN

UNDERCUTS

PLASTICS PRODUCT DESIGN

THREADS -

PLASTICS PRODUCT DESIGN

Metal INSERTS FACTORS TO BE CONSIDERED WITH MOLDED IN INSERTS
I)

It should provide required mechanical strength.

Sufficient anchorage must be provided to prevent
insert from pulling out of the plastic.

II) Some plastic material will crack around the insert as it

ages.
III) Flow of plastic material should not dislodge the insert.
IV) Plastics has higher co efficient of thermal expansion
and contraction than metal.
V)

Insert may be pre heated prior to molding to avoid

cracks around insert.

PLASTICS PRODUCT DESIGN

INSERT -

A ROUND SHOULDER ON
THE TOP PART OF A
HEXAGONAL INSERT
ELIMINATETHE NECESSITY
TO MACHINE A HEXAGONAL
HOLE IN THE METAL MOLD.

PLASTICS PRODUCT DESIGN

NOT PREFERRED

PREFERRED

WHEN STRESSES ARE ENCOUNTERED , INSERT AND NOT

PLASTIC SHOULD BEAR THE LOAD

PLASTICS PRODUCT DESIGN

INSERT -

INCORRECT
CORRECT

METAL INSERT IN BOSSES SHOULD EXTEND TO

WITHIN ONE MATERIAL THICKNESS OF OPPOSITE
WALL AND RIBS CAN BE ADDED FOR ADDITIONAL
SUPPORT

PLASTICS PRODUCT DESIGN

INSERT
MALE INSERT SHOULD HAVE SHOULDER IN ORDER TO SEAL
OUT PLASTIC MATERIAL THAT MIGHT BE FORCED AROUND
THE INSERT

POOR DESIGN
NO SHOULDER OR SEAL

GOOD DESIGN
HORIZONTAL SEAL

BETTER DESIGN
HORIZONTAL &
VERTICAL SEAL

BEST DESIGN
HORIZONTAL &
VERTICAL SEAL

PLASTICS PRODUCT DESIGN

HINGES IN PLASTICS PRODUCT TYPES OF HINGE
A) RATHBUN HINGE IT USES ELLIPTICAL SHAPED STEEL SPRING

B)
C)
D)
E)
F)
G)

CLIPS TO HOLD A BOX LID TIGHTLY CLOSED OR WIDE OPEN. CLIP

ARE PLACED IN SMALL UNDERCUTS OR SLOT . PROVIDES STURDY
SPRING ACTION AND HOLDS COVER TIGHTLY
PIANO HINGE MADE OF METAL , SAME AS USED FOR HINGE COVER
OF PIANO. HINGE RIVETTED OR FIX BY SELF TAPPING SCREW.
LUG & PIN HINGE LEAST EXPESIVE . RECESS DRILLED IN SIDE OF
BOX & COVER IS PROVIDE. METAL PIN IS DRIVEN THRO HOLE
STANDARD PIN HINGE Molded HOLES ARE EXPENSIVE FOR CAM
OPERATION IN MOLD.
INEXPENSIVE PIN HINGE ELIMINATES DRILLING OR CAM
OPERATION
HEAT SEALED HINGE VERY STRONG AND DURABLE. AFTER
ASSEMBLY, TWO TABS ARE HEATED AND BENT PERMANENTLY
AROUND TWO PINS.
BALL GRIP HINGE USED IN SMALL BOXES. BALL SNAPS INTO
TWO DEPRESSION .

PLASTICS PRODUCT DESIGN

HINGES IN PLASTICS PRODUCT
STANDARD PIN HINGE
HINGE

INEXPENSIVE PIN

PLASTICS PRODUCT DESIGN

HINGES IN PLASTICS PRODUCT
RATHBUN HINGE

PIANO HINGE

LUG & PIN HINGE

PLASTICS PRODUCT DESIGN

HINGES IN PLASTICS PRODUCT

HEAT SEALED HINGE

VERY STRONG AND
DURABLE. AFTER
ASSEMBLY, TWO TABS
ARE HEATED AND BENT
PERMANENTLY AROUND
TWO PINS.

PLASTICS PRODUCT DESIGN

CLASPS
MOSTLY WORKS ON FRICTION HOOK PRINCIPLE

PLASTICS PRODUCT DESIGN

SNAP ON FIT

SNAP IN FIT

PLASTICS PRODUCT DESIGN

SNAP FITS

PLASTICS PRODUCT DESIGN

SNAP ON FIT

&

SNAP IN FIT