6/22/2016

PlasticDesignGuide:PartDesign,MaterialSelection,ProcessingConditions
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PLASTICDESIGNGUIDE
APIengineersanddesignerscanworkwithyoutodevelopanddesignyourplasticinjectionmoldedcomponent.To
ensureaqualitypart,therearethreemajorareasoffocusthroughoutthedesignstage:
1.Properplasticpartdesign
2.Propermaterialselectionplasticpartdesign
3.Processingconditionsforplasticinjectionmolding
ThedesignersandengineersatAPIhaveover250combinedyearsofexperienceindesigningpartsforplasticinjection
molding,selectingmaterials,andprocessingresins(specializinginengineeringandhighperformanceresins).Thisguide
wasdesignedtodemonstratethebasicelementsofproperplasticpartdesign.

DESIGNINGPARTSFORUP&DOWNMOLDINGHELPSCONTROLCOST
Designingapartthatcanbemoldedwitha"straightpull"or"up&down"motionisagreatwaytokeepthecostofthe
molddown.Astraightpullmoldisdesignedsothatwhenthetwohalves(AsideandBside)ofthemoldseparatefrom
eachother,thereisnoplasticblockingthepathofthemetalinthedirectionofthepull.Undercutsonthepartcausethis
blockageofpathandrequireanactioninthemold(cams,corepulls,etc.).Actioninthemoldcanhaveamajorimpact
onthecost(andoverallsize)ofamold.
ReadCaseStudies

UNIFORMWALLTHICKNESSHELPSTOPREVENTDEFECTS
Properwallthicknessisoneofthemostfundamentalrequirementsindesigningapartforplasticinjectionmolding.
Plasticshrinksasitcoolswhichcanleadtodefectssuchassinkmarks,voids,stresses,andwarping.Plasticresin
solidifiesinthemoldnearertotheoutsideofthepart(closesttothemoldsurface).Thicksectionsofaparttendtopull
inward,creatingstresses,sinkmarks,orvoids.Sincethinnersectionscoolquicker,stresscanbuildinthepartbetween
thinnerandthickersections,resultinginpartwarpage.

DRAFTALLOWSFORPARTSTORELEASEFROMTHEMOLD
Draftisrequiredonallpartsinthedirectionofmoldmovementinordertoallowpartstoreleaseorejectfromthemold
properly.Draftistheangleinwhichthepartistaperedtoallowittorelease.Asthepartcools,ittendstowanttoshrink
tothecoresideofthemold.Addingdrafthelpstheparttorelease.Mostpartsorapplicationsrequireaminimumof1/2
to1degree,however11/2to2degreesiswidelyacceptedasthenorm.

HOLESENHANCEPARTFUNCTIONALITYANDREDUCEWEIGHT
Holescanbeaddedtoapartforfunctionalityortoreduceoverallpartweight(coring).Corepinsaretypicallyusedto
formahole,preventingthemoltenplasticfromfillinginthatspace.Throughholesgoallthewaythroughapart.Blind

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PlasticDesignGuide:PartDesign,MaterialSelection,ProcessingConditions
holesdonotcompletelygothroughapart.Corepinsforablindholeareonlysupportedbyoneend,sothereisagreater
degreeofdifficultyinformingthemwithoutdefect.Formingholescanleadtodefectsorhaveanegativeimpacton
aesthetics.Sincethemoltenplasticflowsaroundthecorepin,itcanleaveaweldline(whichmaybevisibleand/orbe
weakerthantheremainderofthepart).

1.Thedepthofablindholeshouldbeabouttwotimesthediameterofthecorepinforsmallpins(lessthan3/16")
andfourtimesthediameterofthecorepinforpinsgreaterthan3/16".
2.Distancefromtheedgeofaholetoaverticalsurface(edgeorpartorrib)oranotherholeshouldbeatleasttwo
timesthethicknessofthepartoratleastthediameterofthecorepin(hole).

3.Holescreatedinthedirectionoftheopening/closingofthemoldorparalleltothepartinglinearerelativelyeasyto
produce.Holesatdifferentanglescanbecreated,butmayrequirespecialactioninthemoldutilizingcorepullsor
camswhichcanhavesignificantcostimpacts.

BOSSESAIDINASSEMBLYANDMOUNTING
Bossescanbeaddedtothepartdesignforassembly,locating,ormountingofapart.Improperplacementofaboss
leadstounevenwallthicknessandcanhaveanegativeimpactontheaesthetics,shrinking,orstrengthofapart.
1.Wallthicknessaroundabossfeatureshouldbe55%65%ofthenominalwallthicknessforthinwalls(lessthan
1/8")oraround40%ofthenominalwallthicknessifgreaterthan1/8"
2.Bossheightshouldbenomorethan21/2timesthediameterofaholeintheboss

RIBSENHANCEPARTSTRENGTHANDSTABILITY
Ribscanbeaddedtopartstoaddrigidityorstiffness.Addingribsallowsforaparttoincreasestrengthandbearahigher
load.Ribstoohaverecommendedguidelinestomaximizefunctionalityandminimizedefects.
1.Ribthicknessshouldbelessthanthewallthickness.Recommendedthicknessis60%to80%ofthenominal
wall.
2.Addingmoreribsaddsmorestrengthorstiffnesstoapart.Itisbettertoaddmoreribsthanmakelargerorthicker
ribs.
3.Ribsshouldbespacedatleasttwotimesthenominalwallthicknessfromoneanother.
4.Ribheightshouldbelessthanthreetimesthenominalwallthicknessofthepart.
5.Ifathickribisrequired,thecenteroftheribshouldbecored(cutout)toallowforuniformwallthickness.

ADDINGARADIUSREDUCESSTRESSONCORNERS
Radiishouldbeaddedtoanglestopreventsharpcorners.Cornerscanleadtostresses,limitmaterialflow,andoften
reducepartstrength.
1.Insideradiusofacornershouldbeatleasthalfofthewallthickness
2.Outsideradiusofacornershouldbeequaltothepartthicknessplustheinsideradius
3.Aradiusbeingaddedtoabossorribshouldbe1/4ofthepartthickness,nosmallerthan.015
Materialselectionandprocessingconditionsareequallyimportantfactorsintheproperdesignforaplasticinjection
moldedcomponentorpart.

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PlasticDesignGuide:PartDesign,MaterialSelection,ProcessingConditions

Weunderstandthatinitially,materialselectionmayseemoverwhelmingsincetherearesomanymaterialstochoose
from.YoucanresteasyknowingthatAPIhaspartneredwithresinsuppliersforover60yearsandhasamultitudeof
experienceinmanufacturingplasticpartswitheventhemostdifficulttoprocessresins.Pleaseseeourbasicresinguide
forafewexamplesofcommodityandengineeringresinsthatAPIhasbecomeanexpertinmolding.
Giveusacalltoday(516)3337577todiscussyourplasticdesignorrequestaquotetoday.

20082016AutronicPlasticsInc.Allrightsreserved.SitebyInnovativeImages.

Buildingcustommoldsandmanufacturing
plasticcomponentssince1953

Ihaveapartnooneelsecando

AutronicPlastics,Inc.succeedswheremanyothermoldershavefailed.APIspecializesinworkingwithdifficulttoprocess,engineeringresinsandhigh
percentageglassfilledmaterials.
APIpartnerswithmultipleresinsupplierstodeterminethebestsuitablematerialforcustomerneeds
RigorousR&Dandtestingcompletedonmaterialstoimproveplasticprocessingandqualityandreducecostofmanufacturing
API'sfullservicemoldshopreducessupplychainleadtimesandimprovesspeedtomarket
Onsitemolddesignersandengineerswith250combinedyearsofexperienceinplasticinjectionmoldingallowustoresolveissuesandpresentsolutions
quickly
KeyIndustries:
Security,Lighting,Military,Medical/Dental,LifeSafety,Aerospace,Healthcare,Automotive,Displays,andmore
AdditionalCapabilities:
PlasticMoldMaking,Engineering,ContractManufacturing,AutomatedandManualAssembly,CellularManufacturing,RapidPrototyping,R&D,
Joining,Decorating,Packaging,andBonding
CallUs:5163337577
EmailUs
RequestAQuote

Ihaveanidea

AutronicPlastics,Inc.canhelpyoubringyourideafromconcepttocompletion.APIisafullservicecustomplasticinjectionmolderthatworkswithcustomersto
designanddevelopnewproducts,engineersprototypes,buildsmolds,andmanufacturesplasticpartsallunderthesameroofinLongIsland,NY.
APImakesandtestsprototypestoensureproductdesignwillmeeteverystandardimaginable.
Fullspectrumplasticproductdesignandengineeringfromideationtocompletedassembly
Designersandengineersworkwithcustomerstocreate2Dprintsand3Dmodelsifneeded
75+clientpatentintheU.S.andInternationalMarkets
RapidprototypingwithinhouseFDMMachine(FusedDepositionModeling)allowourcustomerstohaveaphysicalplasticparttoevaluatepriortomold
construction
API'sprototypeevaluationforfunctionalandperformanceanalysisaswellasmanufacturabilityensuresyourproductisdesigned"RighttheFirstTime"

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PlasticDesignGuide:PartDesign,MaterialSelection,ProcessingConditions

CallUs:5163337577
EmailUs
RequestAQuote

IhaveaDesign

ExperiencedAPIdesignersandengineersworkwithyoudirectlytobringyourdesignconcepttoreality.TheAutronicPlasticsteamworkstoimproveclient
productideasandhelpstodesignplasticproductsformanufacturabilityandcostefficiency.
APIDesignersandEngineerscanworkwithcustomerstocreateorimprove2Dprintsand3Dmodels.
PlasticprototypesarecreatedwithinhouseFDMMachine(FusedDepositionModeling)toreduceoveralldevelopmenttimelineandhelpstobringyour
producttomarketquicker
Customizedrigorousprototypevalidationandtestinghelpstoensurefunctionality,manufacturabilityandcostefficiencyofyourplasticinjectionmolded
part
RighttheFirstTimeDesignNoOverDesignorUnderDesignhelpstobringyourproducttomarketquicklyandefficientlywhileavoidingcostly
aftermarketsolutions
CallUs:5163337577
EmailUs
RequestAQuote

IhaveapartIwanttoreplicate

AutronicPlastics,Inc.canreverseengineermetal,composite,orplasticinjectionmoldedpartsandcanworkwithyoutoredesign,reengineer,orreproduce
thosecomponents.
APIisexperiencedinmoldingallthermoplastics,specializinginengineering,highperformance,andglassreinforcedresins.
Optimizationandredesignservicesforexistingpartstoresolvedesignormanufacturingproblemsandtohelpreduceoverallcost
Highqualityandprecisionapplications
Everydayplasticproductsdesignedenvironmentallyfriendly
MetalReplacementforreducedweight,vibrationandnoisedampening,andlowcorrosion
Rubberreplacementforcut&abrasionresistanceandcostreduction
Nanocompositesforunique,"unplastic"typeperformance
PPAPandaftermarketreplacementforimprovedperformanceandlowercost
CallUs:5163337577
EmailUs
RequestAQuote

INeedhelpwithmyexistingpart

AutronicPlastics,Inc.hasexperiencetransferringexistingplasticinjectionmolds,canreverseengineerexistingparts,andcantroubleshootproblematic
componentstoachievesuperiorperformanceandfunctionality.
TheAPIengineersanddesignershaveover250yearsofcombinedexperienceandstrivetoexceedourcustomer'sexpectations.Ourengineersbecomea
valuableextensionofyourproductdevelopmentteam.

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PlasticDesignGuide:PartDesign,MaterialSelection,ProcessingConditions

Modifications/repairsmadetoplasticinjectionmoldsinouronsitetoolroom
Aftermarketsolutionsforexistingproducts
Everydayplasticproductsdesignedenvironmentallyfriendly
Partnershipwithmultipleresinsuppliersforexpertiseinresinselectionandprocessing
Moldflowanalysistoensurehighestlevelofqualityandbestoverallcost
CallUs:5163337577
EmailUs
RequestAQuote

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