PRODUCT MATERIAL AND METHODS

MATERIALS

TOOLING

ASSEMBLY

DECORATION

INTRODUCTION TO PLASTICS
Objective Overview of plastic materials and uses Choosing appropriate materials to balance design, cost, safety and production requirements Please read : Manufacturing Processes for Design Professionals
Introduction- 418-423 Plastics 423-447

Process, Material, Measurements- Page 84-85 The Not So Technical Technical Aspect of Toy Design- Page 15- 80
Project- Design 3 toys, 0-6 month, 3+ and 8+. Specify materials used and why appropriate. Sketch with various parts called out.

HOMEWORK GUIDLINES
MUST BE 8.5 by 11 PAPER. NO TRACING PAPER MUST BE NEAT AND PRESENTABLE

Grading
2 Quizzes -25% Class Participation and Home work- 25% Final 50%
This is of your Final Grade. The other half will be in the electronics portion of class.

What is Plastic?

What is Plastic?
Plastic is the general common term for a wide range of synthetic or semi synthetic organic solid materials suitable for the manufacture of industrial products Plastics can be clear or opaque, soft or hard, brittle or flexible, light or heavy Versatile, can be low cost, easily used in mass production

They are either THERMOSET or THERMOFORMED

THERMOSET

THERMOFORM

Thermoset
Thermo set plastics cannot be reheated to melt. These plastics cure to the final state by heating or chemical reaction. Once set it cannot be re melted. Cannot be reground (recycled back into raw material) Very Rarely Used In Toys

Used a long time ago

STILL USED TODAY

HIGH HEAT, HIGH DURABILITY ENVIROMENTS

Thermoformed
Thermoformed plastics can be heated and will soften and melt. Can be reground. MOST PRODUCT ARE THERMOFORMED These include:
Polyolefin's (PP, PE, EVA,) Styrene's (PS, HIPS, EPS, ABS) Arylic Cellulosics (CAB) PVC TPEs (Thermoplastic elastomers) Polyesters (PET,PETG) EVA Engineering plastic such as PC, Acetal (POM), Nylon,Tritan

Important properties
Safety and Age Appropriate Impact Resistance Hardness Mold Shrinkage Usable Temperature Flexibility Paintability Ability to be joined

EXTRA CREDIT 1 point per item

Protomold Resin Puzzle

Protomold Cube

Protomold Torus

Protomold Demo Mold

Safety
Avoid Phthalates- Used in Plasticizers to soften plastics (PVC)- Banned by CPSC Avoid BPA (Bisphenal A) for hand to mouth items disrupts the endocrine system Use age appropriate plastics. Infant toys should be more durable, softer plastics

POLYOLEFINS
A polyolefin is a family of thermoplastics derived from the ethylene family of simple olefins. These plastics cannot be solvent joined
Polyethylene (PE) Polypropylene (PP) Ethyl Vinyl Chloride (EVA)

Polyethylene
LDPE- Cheap, High impact, Flexible, Good ESCR, usable temp 160 F LLDPE- High impact, Stiffer, Better ESCR HDPE- Harder and Stiffer, Poorer ESCR, SHRINK -.01 to .04

Examples of PE

Eero Aarnio PUPPY 2005

POLYETHYLINE (PE) ROTATION MOLDED

.25 Wall Thickness

Rigid and Durable Impact resistant Many Colors

Polypropylene (copolymer)
Lower cost than ABS, High fatigue resistance, Impact resistant Dishwasher safe (high melting point 320F) Hard to deco Easily friction/sonic welded but cannot be solvent joined. Shrink rate- .010 -.025 in per inch

Examples of PP (Copoly)
TIC TAC LID
Living hinge Snap closure

Playsets
Good for snap fits Large items Has soft look/feel Slightly translucent Hard to paint/deco, needs additional processing Needs lots of ribs or returns/flanges to maintain structure

Dishwashable

Other PP uses

Styrene
Poly Styrene (GPPS,HIPS,EPS) and ABS Styrene (PS and ABS) can be:
Solvent, friction, sonic welded Clear or opaque (90% light transmission) Easily decorated Vac metalized

LOW SHRINK- .005-.010

Poly Styrenes
GPS- General purpose Styrene
Fair Mechanical strength, impact resistance, Avoid using in childrens toys

HIPS- High impact (K-Resin)

Better impact strength, Can be used toys

EPS- Expanded Poly Styrene (FOAMED)

Used for Packaging materials for cushioning Lightweight

LOW USEFUL TEMP- 140 MAX

GPS MODEL KITS

HIPS (K-RESIN)
Can be used in some toy application Can be used for clear recessed parts

EPS

Acrylonitrile Butadiene Styrene (ABS)

Most common plastic in consumer goods
High impact resistance Naturally Translucent but can be made clear High Gloss Great mechanical properties Poor Fatigue Resistance High Wear (can be used for snap fits) Can Decorated, Vac Metalized BETTER THAN PS

ABS TOYS DURABLE, CAN DECO

Higgly Town Playground

Acrylic
Higher cost than ABS Used for Light piping Not used frequently in toys for main components due to higher cost and impact strength (would use Clear HIPS, PETG) Can be used in internal components and for older age grade

PVC
Can be soft or hard Can mold with undercuts Can be injection molded, roto molded Can contain phthalates (plasticizer) Safer citrate based plasticizer can be used Can be sonic, friction, solvent welded

PVC Samples

Packaging

Figures
Solid injection molded figures, Hollow, soft roto-molded figures Hard PVC tubing (construction) Other examples--

Thermoplastic elastomers (TPE)

Kraton, Styroflex, Pellethane (SBS) TPE/TPO Poly Urethane TPE More cost effective than Thermoset rubber.

TPE SAMPLES

Thermo set Rubber

POLYESTHERS
PET- Homopolymer
Can be clear but difficult to keep clear Used in blow molded bottles High impact

PETG Copolymer
High clarity Easily injection molded High impact NO Bisphenol A (PC contains Bisphenal A)

EVA
Ethyl Vinyl Acetate
Soft Flexible Plasticizer free Bisphenol A free

Soft and Squishy

Engineering Plastics
Acetal(POM)
Delrin/Celcon (trade name) Self lubricating, low friction

Polycarbonate Nylons

NYLONS AND ACETAL

Used for internal, high wear, high pressure parts Strong and fatigue resistant.

Polycarbonate
Amorphous (clear) Temperature resistant High Impact Contains Bisphenol A

Summary
Types of plastics and uses Appropriate materials to balance design, cost, safety and production requirement

Plastics and Safety Overview

Avoid BPA Avoid Pthalates in plasticizers Choose correct plastics for Age Grade

Introduction to Manafacturing

Introduction to Manufacturing Methods Session 7

Assigned reading:
Process, Materials, Measurements
Chapter 3- Page 30 to 46

Manufacturing Processes for design Professionals

Blow Molding- 22-29 Thermo-forming- 30-35 Rotational molding- 36-39 Injection Molding 50- 67 EDM- 254- 259

The Not So Technical Technical Aspect of Toy Design Chapter 16- Page 83 to103

Homework- Design at least 3 toys that use different manufacture methods. Explain why method is used. Also label material used and why.

Most Common methods in Toy Manafacturing

Injection Molding Rotational Molding Blow Molding

COMMON TERMS
MOLD/TOOL- This is what the plastic is injected, poured or formed into and gives it its final shape. Process will determine number of parts and material the mold/tool is made. CORE and CAVITY, SLIDES and CAMS- These parts make up the Mold/Tool depending on part complexity. UNDERCUT- This is a feature in the final part that will prevent the item from being removed from the tool. Depending on the process and complexity of the tool and material used these features can be kept. RIBS- Features that are added to strengthen a part. BOSS- Support that screws thread into. SINK MARKS- Surface deformation due to a rib on other side of part. These can be minimized by adjusting rib thickness. WALL THICKNESS- Thickness of material at a given section. DRAFT- Angle that will allow part to be removed from tool.

INJECTION MOLDING
Most item are injection molded. Most thermoformed plastics can be injection molded Many different types Single shot injection Molding Multi shot injection molding (over molding) In mold Decoration Reaction injection molding

WHY INJECTION MOLDING?

Very tight tolerances for mating parts. Can design tool to compensate for material shrink. If the toy is made of a lot of separate parts, injection molding the parts will ensure a better fit. Surface finish is excellent and can reproduce lots of detail. Detail is superior to any other method (rotational molding, blow molding, etc) Can injection mold all thermo-form plastics Can create undercut features by use of cams Can create a a single part that has 2 types of material (over molding, insert, molding) Can create a part with decoration (in mold decoration)

Basic Process

Animated Injection Molding Machine

Injection Molded Parts

Simple Single Direction Tool (NO CAM/SLIDES) ANIMATION

Multi Core and Cavity and parts

Cavity

Core

Parts on Sprue

Tool with Slides/Cams Animation

Tool with cams or slides

These car bodies were injection molded with 3 or more slides. Can you find the witness lines?

ROTO MOLDING BASICS

USED TO MAKE HOLLOW PARTS PLASTIC (pellets, powder, liquid) is put into tool. TOOL is sealed and tranfered to heated chamber TOOL is rotated in 2 axis to distribute material and form consistant wall thickness TOOL is moved to cooling chamber and rotated in 2 axis and allowed to cool slightly TOOL is opened and item is removed

ROTO MOLDING RIGID PLASTIC

Use to create hollow parts. Mold consist of at least 2 parts Lower tool cost than injection molding PE and PP most common plastic Low scrap (material is carefully measured)

Rigid Roto Products

CASE STUDY

Eero Aarnio PUPPY 2005

ROTO MOLDING SOFT PVC

PROCESS SIMILAR TO ROTOMOLDING RIGID PLASTIC SOFT PVC PRODUCTS CAN BE MOLDED WITH LOTS OF UNDERCUTS MOLD USUALLY MADE OF COPPER MOLD IS USUALLY SINGLE PIECE

CREATE THE PATTERN

APPROVED FINAL PATTERN SUPPLIED. THIS IS CALLED THE REFERENCE PATTERN

MAKE INVESTMENT PATTERN

REFERENCE SAMPLE IS DUPLICATED IN WAX AND MODIFICATIONS MADE TO ENSURE PROPER MOLDABILITY. THIS IS CALLED THE TOOLING PATTERN

CREATE THE COPPER MOLD

PATTERN IS SUBMERGED INTO A COPPER BATH AND IS COATED WITH COPPER UNTIL A SUFFICIENT WALL THICKNESS BUILDS UP. THIS CAN TAKE UP TO 7 DAYS

FINISHED MOLD

A HOLE IS MADE IN THE BOTTOM AND A REPLACABLE PLUG IS CREATED. THE WAX PATTERN IS MELTED OUT.

ADD PLASTEROL (PVC)

PLASTEROL IS ADDED, PLUG REFITTED AND TOOL IS ROTATED IN HEATING CHAMBER, THEN ALLOWED TO COOL.

Item is removed

While plastic is still hot and pliable, plug is removed and a hook is inserted and item is removed through the opening. Item cools into final shape. If more than 1 tool is needed (larger production runs) the final tools are made from these vinyl patterns.

Soft PVC Toys

Blow molding
Blow molding uses air to form the part. Used for thin walled hollow part (bottles) Less costly than injection molding Less detail than injection molding Less detail than Rotational molding

Animations of Blow Molding

Animations of Blow Molding

Samples Blow molded products

ASSEMBLY

Lecture 9 Introduction to Assembly methods

Objective Overview of different ways to assemble toy. Please read : Process, Material, Measurements- Page 51-53 The Not So Technical Technical Aspect of Toy Design- Page 107-110
Manufacturing Processes for design Professionals
Vibration Welding 298-301 Ultra Sonic Welding- 302-307 Staking 316-319 Injection Molding 50- 67

Project- Disasemble some toys I brought to class. Take photos of describe toy different methods used. Find 10 examples, at least 3 different types (ie snap fit, sonic weld, screws) DUE 2 weeks after lecture. Due Via Email.

Assembly Method
All multi part products need some type of assembly These include mechanical fasteners, solvent bonds, heat welding, sonic welding, insert molding,heat staking and consumer assembly

Common Assembly methods

Screws Rivits, Peened Axles ends, knurled/ringed shaft Snap fits Spin welding Ultra-sonic welding Solvent welding

Screws

Screws

Rivets, Peens and Axles

Rivets are use to assemble 2 parts together that can not be screws or glued. Material may be to hard or thin to use self tapping screws. Peens are flattened ends of axles or post that create T or mushroomed end that prevents the part from coming off. Axles are used for parts that need to spin or rotate. The ends of the axles can be knurled, ringed or peened over.

Snap fits
Used for one time assembly, break away hinges for safety, consumer assembly Requires no additional parts. Snap is integrated into part. Material used depends on if item will be disassembled frequently

Spin Welding

Uses the heat form rotational movement to fuse 2 parts together

Spin Welded Products

Ultra-sonic welding
Vibrates 2 thin parts by using a piezo disc to fuse the 2 parts together. Very efficient use of energy, little heat generated, welds in about 1 second Useful for joining 2 noncircular part together (cannot be spin welded) Useful for joining clear plastic together where solvent welding may blemish part.

Material considerations
Can Sonic Weld all thermoformed plastics ABS, PC (poly carbonate),PS (poly styrene) can be welded to one another PP, PET, PE, can only be welded to the same material (PP to PP, PET to PET, PE to PE only)

Solvent welding
Used to join similar plastics like styrenes together. Economical Cannot Solvent weld PP,PE,acetal,nylons

LECTURE 9 DECORATION
Objective Overview of process and types of decoration to enhance your toy Please read : Process, Material, Measurements- Page 46-50 The Not So Technical Technical Aspect of Toy Design- Page 113-118 Manufacturing Processes for design Professionals
Spray Painting 350-355 Vacuum Metalizing 372-373 Pad Printing 404-407 Hydro-Transfer 408-411 Foil Blockinging and Embossing 412-415 IInmold Decoration 62-63

Project- Design 3 toys using different decoration. DUE 2 weeks after lecture. Due Via Email.

DECORATION

Most items will have some sort of decoration to enhance the product. This can be as simple and inexpensive molded in decoration to after molding operations such as tampo printing hand painting, and metalizing. Process include Molded in decoration, in mold decoration (IMD), label application, tampo or pad printing, hand painting (masks and brushes), Hydro graphics, hot stamping, vacuum metalizing,

Molded in and In mold decoration

Molded in- textures, plastic color, color additives, glitter and metaflake, pearlescents, fluorescent, phosphorescent. There is no additional cost other than material. Cost effective way add value to an item In Mold decoration (IMD)- This is a process during molding which a thin film is inserted into the mold and the material is injected the film and the material fuse together. It is high in cost because of the labor to place the film and the cost per piece of each film.

Molded in Textures and Graphics

Examples of molded in decoration HOLGA CAMERA

Pigments and Dyes

You can add other material into plastic while molding. Adds value with out labor cost Can add, glitter/metaflake, dyes/tints (for clear items), Pearlescent, phosphorescent,

SHIMMER PHONE (LITTLE MS SPIDER)

In- Mold Decoration (IMD)

Molding Process Preformed Film with Graphics inserted into tool and material is injection molded and part is fused together. Controllable Decoration and placement of film Need Special tools, higher labor cost, need to design Graphic and part shape early in design Process

IMD Process

LABEL ART
Label art cost effective way to introduce color into product. 4 color process is most common. You can can get as many colors you want for the same cost. Cost determined by label surface are and number of labels to be applied. Good way to add color to PP, PE (cannot be painted)

LABEL SAMPLES

Tampo Process Overview

Silicone Key pad Tampo

TAMPO PRINTING
Sharp Edges and lines. Great for Graphics Can register multiple passes/color Can wrap around curved surfaces (less than 180 degrees, about 150 degress) Automated so less costly than hand painting Not for applying to a large surface (max 4x4 inches)

Tampo decoration

Hand Painting
Color is applied by hand Can use masking techniques to avoid painting unwanted surfaces Can paint large or small surfaces Can use brushes to hand paint stripes, highlights, small details

Hydro Graphics
Also called water transfer, immersion printing, aqua graphics A cost effective way to wrap a graphic or pattern around an entire part. Pattern placement is approximate, cannot get a high degree of registration. Each part will be different

Hot Stamping
Also called Foil Stamping Similar to Tampo but uses heat and a rigid tool to tranfer foil (on rolls) to a part. Can give a part a metalic or chrome finish Part surface cannot be too complex

Hot Stamp Overview

Vacuum Metalize
Also called Vac Metal or Sputtering Can vac metal rigid plastics and metals. Flexible plastics are not suggested because the finish will crack and flake off. Can apply any metal (aluminium, brass) Must metalize entire part (cannot mask or selectively metalize surfaces.

Vac metal samples

RAPID PROTOTYPING

LECTURE 9 DECORATION
Objective Overview of process and types of decoration to enhance your toy Please read : Process, Material, Measurements- Page 73-77 Manufacturing Processes for design Professionals
Rapid Prototyping 323-241 CNC 182-189 Rotational molding- 36-39 Injection Molding 50- 67 Project- Design 3 toys using different
decoration.

DUE 2 weeks after lecture. Due Via Email.

LECTURE 10 RAPID PROTOTYPING

Manufacturing Processes for design Professionals
Rapid Prototyping 323-241 CNC 182-189 Rotational molding- 36-39 Injection Molding 50- 67