Moulds Design

Awareness on Plastics &Moulds
H & GT - GTCI - Bangalore - July 2005 2

Contents
> Introduction
> Materials
> Mould Manufacturing
> Advanced Moulding Technology
> Injection Moulding Machine
> Moulding defects and remedies
> Design Considerations
> Design Guidelines
> Design for Manufacturing and Assembly Guidelines

Introduction to Moulds
What is mould?
Moulding is a manufacturing technique for making parts from plastic material.
•Molten plastic is injected at high pressure into a mold, which is the inverse of
the desired shape.
•The mould is made by a mold maker from metal, usually either steel or
aluminum, and precision-machined to form the features of the desired part.
•Injection moulding is very widely used for manufacturing a variety of parts,
from the smallest component to entire body panels of cars.
4 M’s to be
considered
Man Why is injection moulding awareness needed for Product Designing ?
Material
Considerable thought should be put into the design of moulded parts and their
Manufacturing
moulds, to ensure that the parts will not be trapped in the mould, that the moulds
Machine
can be completely filled before the molten resin solidifies, and to minimize
imperfections in the parts, which can occur due to peculiarities of the Design
Process.

Materials > General Definition of Materials
Material is the substance or matter from which something is or can be made, or
also items needed for doing or creating something.
Materials for moulding:

1. Natural Rubber.
2. Synthetic Rubber
3. Thermoset Plastic.
4. Thermo Plastic.

Materials > Criteria for selecting Materials
Physical & Mechanical Considerations
•What are the overall part dimensions (diameter, length, width,
thickness)?
•What load will the part have to carry?
•Will the design carry high loads?
•What will the highest load be?
•What is the maximum stress on the part?
•What kind of stress is it (tensile, flexural, etc.)?
•How long will the load be applied?
•Will the load be continuous or intermittent?
•Does the part have to retain its dimensional shape?
•What is the projected life of the part or design

Thermal Considerations
•What temperatures will the part see and for how long?
•What is the maximum temperature the material must sustain?
•What is the minimum temperature the material will sustain?
•How long will the material be at these temperatures?
•Will the material have to withstand impact at the low temperature?
•What kind of dimensional stability is required (is thermal expansion and
contraction an issue)?
Note:
Materials filled with Bearing and Wear Considerations
friction reducers •Will the material be used as a bearing? Will it need to resist wear?
(such as PTFE,
molybdenum •Will the material be expected to perform as a bearing? If so, what will the load,
disulfide, or shaft diameter, shaft material, shaft finish, and rpm be?
graphite) generally •What wear or abrasion condition will the material see?
exhibit less

Chemical Considerations
•Will the material be exposed to chemicals or moisture?
•Will the material be exposed to normal relative humidity?
•Will the material be submerged in water? If so, at what temperature?
•Will the material be exposed to steam?
•Will the material be painted? If so, what kind of paint?
•Will the material be glued? If so, what kind of adhesive will be used?
•Will the material be submerged or wiped with solvents or other chemicals? If so,
which ones?
•Will the material be exposed to chemical or solvent vapors? If so, which If so,
which ones?
•Will the material be exposed to other materials that can outgas or leach
detrimental materials, such as plasticizers or petroleum-based chemicals?

Other Miscellaneous Considerations
Will the part have to meet any regulatory requirements?
Is UL94 Flame retardant rating required? What level?
Should the material have a special color and/or appearance?
Natural | White | Black | Other Colors
Color match to another part or material?
Window-Clear | Transparent | Translucent | Opaque
Smooth | Polished | Textured | One-Side or Both
Will the part be used outdoors?
Is UV Resistance needed?
Is static dissipation or conductivity important?
Insulator | Static Dissipative | Conductive

Materials > Rubber
1. A naturally gifted plastic.
2. Has many applications in industrial and consumer goods.
3. Only group of materials able to provide elastic properties across a wide range
of temperatures.
The rubber family includes a diverse range of materials - as varied as
"metals" or "plastics".

Materials > Introduction to Rubber Manufacturing
Rubber The two types of rubber in common use today are Natural and Synthetic.
Natural rubber comes from the rubber tree (Hevea brasiliensis).
When a tree matures at the age of six or seven years, the latex is collected from
a diagonal incision in the tree trunk. The tapping process does not affect the
health of the tree and the tree wound later heals itself.
Synthetic rubber is made by man from petrochemical feedstock. Crude oil is
the principal raw material.

Materials > Uses of Rubber
Rubber
Designers choose rubber because of
its wide range of properties
It can be used over a temperature
range from -80°C to +300°C
It can be electrically insulated,

conductive or anti-static

Rubber
It is available in a wide range of
colors and textures
It can withstand extremes of

weather and outdoor environment

Rubber It can withstand exposure to fuels,
oils and chemicals while retaining its
properties
It can be made flame retardant and
self extinguishing, with halogen free
and smoke suppressant types
available
It can absorb vibration and noise and act

as an insulator

Rubber It can maintain tension and compression forces indefinitely - for example in
seals. It can be gas tight and used as a fluid seal or separator
Gaskets and
Oil Seals
used in Engine

Rubber
It has low thermal conductivity and
can be used to reduce heat transfer
It has friction properties similar to human

skin and is comfortable to grip

Rubber
It can have a clean, smooth
surface which is non-stick and
suitable for hygienic applications
It is compatible with other

engineering materials (e.g. metals,
plastics and ceramics) and can be
combined with them in many
different ways, including bonding.

Materials > Plastics
The term plastics covers a range of synthetic or semi-synthetic organic
condensation or polymerization products that can be molded or extruded into
objects or films or fibers.
•Their name is derived from the fact that in their semi-liquid state they are
malleable, or have the property of plasticity.
•Plastics vary immensely in heat tolerance, hardness, and resiliency.
•Combined with adaptability, the general uniformity of composition and lightness
of plastics ensures their use in almost all industrial applications today.
•Plastic may also refer to any material characterized by deformation or failure
under shear stress.
•Plastics offer extraordinary advantages in product manufacturing. Because they
are easily softened or melted, they can be molded into almost any shape.
•Plastics have replaced traditional materials like metals and wood in countless
applications because of their cost effectiveness and property attributes.

Materials Plastics can be divided into two processing groups
Plastics Thermoplastics and Thermosets
Thermoplastic
1.It is heated and pressed into a mould.
2.No chemical reaction of any kind takes place.
3.Once the plastic has cooled and hardened in this shape, it could be reheated
and remoulded without any perceptible change in its properties.
Granules Products

Materials
Thermosets
Plastics
1. Undergo chemical change while they are being formed.
2. They react by polycondensation and cross-link to form a three-dimensional
lattice.
3. Once a thermoset has achieved its final shape, it cannot be reformed.
4. Examples of thermosets are phenolic resins, melamines and urea resins
Granules Products

Materials Advantages of Plastics
Plastics Plastics can provide the following advantages for product designers and
manufacturers:
•Design Flexibility
•High Strength and Toughness
•Corrosion Resistance
•Reduced Manufacturing Costs
•Almost Any Color or Surface Texture
•Waterproof
•Stiffness or Ductility
•Low Weight
•High Manufacturing Throughput
•High Reproducibility of Parts
•Electrical Insulation
•Thermal Insulation

Materials Different types of Plastics
Plastics •Polyethylene (PE)
•Polyurethane (PU)
•Polypropylene (PP)
•Polyethylene Terephthalate (PETE)
•Polyamide (PA) or Nylon
•Polyester
•Polyvinyl Chloride (PVC)
•Polycarbonate (PC)
•Acrylonitrile Butadiene Styrene (ABS)
•Acetal

Materials Polyethylene (PE)
Plastics Polyethylene or polyethene is one of the simplest and most inexpensive polymers.
It is a waxy, chemically inert plastic.
Properties: Uses
•Thermoplastic. Film, bags, pipe and tubing,
insulating sleeves, bottle stoppers,
•Toughness lids, plastic wrap, toys.
•Ease of processing
•Chemical resistance
•Abrasion resistance
•Electrical properties
•Impact resistance
•Low coefficient of friction
•Near-zero moisture absorption
•Translucent.

Materials Polyurethane (PU)
Plastics Polyurethane is a unique material that offers the elasticity of rubber combined with
the toughness and durability of metal
Properties: Uses
•Abrasion resistant Belts, Metal forming pads, Wear
•Oil and solvent resistant strips, Bumpers, Gears, Bellows,
Machinery mounts, Cutting Surfaces,
•Load bearing capacity
Sound-dampening pads, Chute and
•Tear resistant hopper liners, Prototype machined
•Weather resistant parts, Foam, Gaskets, Seals,
Rollers, Roller covers, Sandblast
•High flex-life
curtains, Diaphragms
•Electrical insulating properties
•Heat and cold resistant

Materials Polypropylene (PP)
Plastics Polypropylene is an economical material that offers a combination of outstanding
physical, chemical, mechanical, thermal and electrical properties not found in any
other thermoplastic.
Properties: Uses
•Thermoplastic
Household items, plastic wrap,
• Lightweight automobile parts, batteries,
•High tensile strength bumpers, garden furniture, syringes,
•Impact resistant bottles, appliances
•High compressive strength
•Excellent dielectric properties
•Resists most alkalis and acids
•Resists stress cracking
•Retains stiffness and flex
•Low moisture absorption
•Non-toxic
•Non-staining
•Easily fabricated
•High heat resistance

Materials Polystyrene (PS)
Plastics Polystyrene is a polymer made from styrene, a liquid that is commercially
manufactured from petroleum, although it is also found in plants.
Properties: Uses
•Thermoplastic Plastic wrap, kitchen utensils,
•Transparent furniture covers, thermal insulation,
toys, office supplies, disposable
•Nontoxic razors
•Optical and electrical properties
•Easy to color
•Resistant to X rays, oils, and grease

Materials Polyethylene Terephthalete (PETE)
Plastics Polyethylene terephthalate (aka PET, PETE, PETP) is a plastic resin of the
polyester family, used to make some thermoforming applications. It is also one of
the most important raw material for man-made fibers.
Its main virtue is that it is fully recyclable as you can recover its polymer chains,
unlike most other plastics
Properties: Uses
•Thermoplastic Soft drink bottles, peanut butter jars,
salad dressing bottles, non
•Extremely hard breakable bottles
•Wear-resistant
•Dimensionally stable
•Resistant to chemicals
•Good dielectric properties.

Materials Polyamide (PA) or Nylon
Plastics Nylon is a condensation polymer made of repeating units with amide linkages
between them: hence it is frequently referred to as a polyamide. It was the first
synthetic fibre to be made entirely from inorganic ingredients: coal, water and air.
Properties: Uses
• Very good physical properties Electrical connectors, gear, slide, cams and
bearings, cable ties and film packaging, fluid
• Moisture has significant effect on reservoirs, fishing line, brush bristles,
properties automotive oil pans, fabric, carpeting,
• Very good heat resistance sportswear, sports & recreational equipment
• Excellent chemical resistance

• Excellent wear resistance
• Moderate to high price
• Fair to easy processing

Materials Polyester
Plastics Polyester is a category of polymers which contain the ester functional group in
their main chain.
Properties: Uses
• Strong Filters, conveyor belts, sleeping bag
insulation, coat insulation, tire cords.
• Resistant to stretching and
shrinking
• Resistant to most chemicals
• Quick drying
• Crisp and resilient when wet or dry
• Wrinkle resistant
• Abrasion resistant
• Easily washed

Materials Polyvinyl Chloride (PVC)
Plastics Polyvinyl chloride is produced from its monomer, vinyl chloride. PVC is a hard
plastic that is made softer and more flexible by the addition of phthalates. Polyvinyl
chloride (PVC) is a flexible or rigid material that is chemically non reactive..
Properties: Uses
• High strength Nuts, filters, signs, tanks, pipes, bolts, valves,
bushings, tank and pool liners, laboratory equipment
• Economical ducts, sprinkler systems, photo mounting, wall
• Dimensional stability coverings, pump parts, fittings
• Good weather resistance

• High impact strength
• Clarity
• Colorability
• Flexible or rigid
• Chemically inert
• Ease of fabrication
• Tasteless, odorless, non-toxic
• Good electrical properties

Materials Polycarbonate (PC)
Plastics Polycarbonates are a particular group of polymers that are moldable under heat;
as such, these plastic are very widely used in modern manufacturing. This
versatile thermoplastic maintains its properties over a wide range of temperatures,
from -40"F to 280"F.
Uses
Properties:
Lenses, high temperature and pressure
• Thermoplastic windows,face shields industrial equipment and
housing components, medical equipment
• High dielectric strength components, instrument components, electrical
insulators and connectors
• Unbreakable
• Machinability
• High impact strength
• Dimensional stability
• Thermal stability
• Stain resistant
• Non-toxic
• Low water absorption

Materials Acrylonitrile Butadiene Styrene (ABS)
Plastics Acrylonitrile butadiene styrene, or ABS is a common thermoplastic used to make
light, rigid, moulded products.
Properties: Uses
• Good chemical resistance Machine parts, prototypes, tote bins and
• Stress cracking resistance to trays, automotive parts, business machine
inorganic salt solutions, alkalis, housing and parts, aircraft interior trim,
acids, and some oils industrial enclosures
• Excellent abrasion resistance

• Electrical properties
• Moisture
• Creep resistance .

Materials Acetal
Plastics Acetal is a crystalline thermoplastic polymer with a high melting point. It is suitable
for mechanical parts or electrical insulators that require structural strength at
above normal temperatures.
Uses
Properties:
Pump and valve components,gears,bearings,
• High modules of elasticity. bushings, rollers, fittings,electrical insulator
• High strength and stiffness. parts
• Low coefficient of friction.

• Good abrasion and impact
resistance.
• Low moisture absorption.
• Excellent machinability.
• Natural lubricity.
• Resistant to gasoline, solvents,
and other neutral chemicals.

Materials Special Purpose Materials
Sheet Moulding
SMC or Sheet Moulding Compound
Compound
Definition:
•A fiber glass reinforced thermosetting compound in sheet form, usually rolled into
coils interleaved with plastic film to prevent auto adhesion.
•Made by dispensing mixed resin, fillers, maturation agent, catalyst and mold
release agent onto two moving sheets of polyethylene film.
•The lower one also contains chopped glass roving or glass mat. SMC can be
molded into complex shapes with little scrap.
Advantages
•Processing of SMC by compression or injection moulding enables the production
of bodywork or structural automotive components, and electrical or electronic
machine housings in large industrial volumes.
•The process also penetrates sectors such as sanitary ware (baths) and urban
furniture (stadium and cinema seating) etc.

Materials Composition of SMC
Sheet Moulding
SMC or Sheet Moulding Compound
Compound

Materials SMC Manufacturing Process
Sheet Moulding
Compound

Materials Advantages of SMC
Sheet Moulding
Compound Part Consolidation:
A well designed composite part can easily eliminate the assembly of many metal
parts by allowing you to mold them as one complete piece. In addition, inserts
can be molded into the SMC material to aid in the assembly process.
Design Flexibility:
Parts molded in polyester or vinylester composite materials can reproduce
almost any shape desired.
Dimensional Stability:
Products made from composite materials offer a greater degree of dimensional
stability when compared to thermoplastics, wood, and some metals.
Light Weight:
Composite parts offer more strength per unit of weight than any un-reinforced
plastic and most metals.
High Strength:
Composite parts can be designed to provide a wide range of impact, tensile, and
flexural strength properties, depending on the specific requirements of the
application.

Materials Advantages of SMC
Sheet Moulding Corrosion Resistance:
Compound Composites do not rust or corrode, and offer various levels of chemical and
environmental resistance.
Low Electrical and Thermal Conductivity:
Composites can offer a wide range of insulating properties to meet specific
requirements for electrical and thermal resistance.

Materials SMC Components
Sheet Moulding
Compound

Materials Special Purpose Materials
Bulk Moulding
DMC or Dough Moulding Compound
Compound
Also called as BMC or Bulk Moulding Compound
Definition:
Molding compound consisting of thermosetting plastic resins mixed with stranded
reinforcement, fillers, and other additives. This viscous compound can be used for
compression or injection molding.
DMC is a combination of chopped glass strands with resin in the form of a bulk
prepreg.
BMC is suitable for either compression or injection moulding.
Injection moulding of BMC is used to produce complex components such as
1. Electrical equipment
2. Car components (headlamps are an important application for BMC)
3. Housings for electrical appliances
4. Tools, in large industrial volumes.

Materials Composition of BMC
Bulk Moulding
Compound
BMC or Dough Moulding Compound
BMC Manufacturing Machine

Materials Advantages of BMC
Bulk Moulding
Compound Technical Advantages:
•Very rigid and stiffer than thermoplastics
•Ability to integrate all the housing functions
•No mechanical rework needed
•No paint: BMC can be mass coloured
•Reduced cycle time compared to aluminium
•Longer life of BMC tools
•Dimensional stability and higher precision compared to aluminium
•Noise reduction : BMC has a dampening effect on vibrations
Economic Advantages:
•50 % total cost savings in comparison to cast aluminium

Materials BMC vs. Thermoplastics
•Dimensional accuracy
Bulk Moulding
Compound •Dimensional stability (creep resistance) over a broad range of temperatures
•Good property retention over long term / high temperature conditions (ageing)
•Low thermal linear expansion (same as steel)
•High mechanical properties (strength, stiffness and impact)
•Excellent electrical properties
•Design flexibility, thin to thick variable component sections
•Inserts can be integrated in the moulding process
•Direct screw assembly without previous threading
•Corrosion resistance in aggressive environments including solvents
•Non-melting, flame retardant , low smoke density, low toxicity and no halogens
•Fire resistant UL94 V-0; glow wire 9600
•Customizing to meet specific needs, good speed to market
•BMC can be mass coloured to match customer specifications
•Lower mould cavity pressure
•Faster cycle time (at medium to high wall thickness)
•Machine workability
•Low cost per litre

Materials BMC Components
Bulk Moulding
Compound

Materials Types of Moulds
Mould
(Manufacturing)
1. Compression Mould
2. Transfer Mould
3. Extrusion Mould
4. Injection Mould
5. Hot Runner Mould.
6. Blow Mould

Types of Moulds Compression Moulds
Compression Moulding is one of three processes used to mold parts.
Compression molding is the oldest and simplest way to make products. In
some specific applications, compression molding is still the best way.
To put it simply, compression molding involves squishing a chunk of uncured
material into a pocket in the mould. After time, heat and pressure the material
cures in the shape of the pocket. The mold can then be opened and the part
removed
Step #1 - A piece of uncured material is placed in the mold.
Step #2 & 3 - The mold is closed up and held under hydraulic pressure while the
material cures.
Step #4 - When the mold opens the part can be removed. The excess material,
called flash, needs to be trimmed off the part.

Types of Moulds Parts of Compression Moulds
Compression Moulds
Compression Mould - Closed

Types of Moulds Advantages & Disadvantages
Compression Moulds
Advantages of Compression Molding
Lowest cost molds
Little "throw away" material provides advantage on expensive compounds
Often better for large parts
Disadvantages of Compression Molding

Offers least product consistency
Difficult to control flash
Not suited for some types of parts

Types of Moulds Transfer Moulds
Transfer Molding involves having a "piston and cylinder"-like device built into the
mold so that the rubber may be squirted into the cavity through small holes.
Pot Transfer Molding
Step #1 - A piece of uncured material is placed into a portion of the mold called
the "pot." The plunger (on the top-most part of the mold) fits snugly into the "pot."
Step #2 - The mold is closed up and under hydraulic pressure the material is
forced through the small hole (the ”sprue") into the cavity. The mold is held closed
while the material cures.
Step #3 - The plunger is raised up and the "transfer pad" material may be
removed and thrown away. Mold is opened and the part can be removed. The
flash and the gate may need to be trimmed.

Types of Moulds Plunger Transfer Molding
Transfer Moulds
Step #1 - A piece of uncured material is placed into a portion of the mold

called the "pot." The plunger (on the top-most part of the mold) fits snugly into
the "pot."
Step #2 - The mold is closed up and under hydraulic pressure the material is
forced through the “cull” and to the gate into the cavity. The mold is held
closed while the material cures.
Step #3 - The plunger is raised up, Mold is opened and the part can be
removed. The flash and the Cull may need to be trimmed.

Types of Moulds Movie - Transfer Mould Operation
Transfer Moulds

Transfer Moulds
Advantages of Transfer Molding

•Provides more product consistency than compression molding
•Cycle times are shorter than compression molding
•Better than compression molding for rubber-to-metal bonding
Disadvantages of Transfer Molding

•The transfer pad is scrap
•Cycle time is longer than injection molding
•Product consistency is poorer than injection molding

Types of Moulds Extrusion Moulds
Extrusion moulding is a method used to form thermoplastic materials into
continuous sheet film, tubes, rods, and other shapes, and to coat wiring and cable.
The process produces continuous two dimensional shapes like sheet, pipe, film,
tubing, gasketing, etc.
The material is fed into the extruder where it is melted and pumped out of the
extrusion die.

Types of Moulds Movie - Extrusion Mould Operation
Extrusion Moulds

Types of Moulds Blow Moulds
Blowing molding is the primary method to form hollow plastic objects such as
soda bottles.
Blow molding is another common type of plastic molding. In this process a plastic
tubular form, produced by extrusion or injection molding, is used to form the part.
This form, called a parson, is softened inside a mold and then injected with air or
other compressed gas. This expands the parson against the sides of the mold
cavity, forming a hollow object the size and shape of the mold.
Step #1 - The Parision is Extruded from injection Unit
Step #2 - The mold is closed onto Parision and then the Parision is inflated
against the walls of the Mould by using a Air.
Step #3 - The Mould is opened and the Part is collected

Types of Moulds 2 Movies - Blow Mould Operation
Blow Moulds
Blow Mould

Types of Moulds Injection Moulds
Injection Molding is the most advanced typical method of molding plastic
products. Injection molding produces the most consistent results by automating all
aspects of how the material gets into the mold. In injection molding, the material is
worked and warmed and then squirted into the mold at controlled speeds,
pressures and temperatures.
Step #1 - Mold is closed and clamped.

Step #2 - A shot of melt is injected under high pressure into the mold cavity.
Step #3 - The screw is rotated and retracted and the polymer in the mold has
completely solidified.
Step #4 - The mold is opened, and the part is ejected and removed.

Types of Moulds 4 major steps in Injection Moulding
Injection Moulds

Injection Moulds
Advantages of Injection Molding

•Provides the maximum product consistency
•Allows the most control of flash
•Because the material is warmed before going into the mold, fastest cycle times.
Disadvantages of Injection Molding
•Not suited for all compounds
•Most expensive molds
•Typically has some runners or other "throw away" portion in each shot

Types of Moulds Parts of a typical mould base
Injection Moulds

Injection Moulds
Top Half Locating Ring:

This part is fitted on to the front face of the mold to serve the
purpose of locating the mould in the correct position in alignment
to the machine nozzle and directly align the sprue bush hole.
Sprue Bush:
It is the connecting member between nozzle and the runner
system.The plasticized material is transferred to the
impression through a passage termed as a “Sprue”. The
Sprue Bush radius is always more than the nozzle radius to
avoid leakage of plastic material.
Top Clamp Plate:

It is the top most part of the mould assembly and is used
for clamping top assembly on the machine platen.

Injection Moulds
Top Half Cavity Plate ( A Plate)

This plate incorporates the cavity inserts and also help to
incorporate cooling media into the mold
Guide Pillars
The accurate mould assembly need the perfect alignment
between top half and bottom half at any point of time in a
mould cycle.The needed services is provided by guide pins
which guided into the guide bush in other half.
Cavity
The space inside a mold into which material is injected. The
material injected will take the form of the cavity profile.

Injection Moulds
Core Plate ( B Plate)
Bottom Half This plate incorporates the Core inserts and also help to
incorporate cooling media into the mold
Guide Bush
The accurate mould assembly need the perfect alignment
between top half and bottom half at any point of time in a
mould cycle.The needed services is provided by guide bush
which guides the guide pillar in other half.
Support Plate
This plate will give extra support for core plate. Which
reduces the deflection caused by injection force.

Injection Moulds
Ejector Pins
Bottom Half Pins that are pushed into a mold cavity from the rear as the mold
opens to force the finished part out of the mold.
Ejector Return Pin
Pins that push the ejector assembly back as the mold closes.
Also called surface pins or return pins
Sprue Puller Pin

This member pulls the Sprue from the Sprue Bush. This
can also be used as a cold slug well by reducing the height
from parting line.

Injection Moulds
Ejector Retainer Plate
Bottom Half This plate will retain the ejector pins in its position as the ejector
assembly is pushed back.
Ejector Plate
The Ejector Plate is clamped to Ejector Retainer Plate. As the
mold opens the ejector rod pushes the ejector plate (assembly),
which results in ejection of component
Ejector Housing
This is the bottom most part of the mould assembly and is
used for housing the ejector assembly and also for
clamping to the moving platen of the moulding machine

Injection Moulds
Locating Ring Sprue Bush
Plastic Part
A-Plate
Guide Pillar
Cavity
Core Guide Bush
B-Plate
Retainer Pin
Ejector Pin
Ejector
Ejector Retainer
Housing Plate
Ejector Plate
3D View of the
Mould Parts Guided Ejection Support Pillar

Types of Moulds Types of Injection Moulds
Injection Moulds

Types of Moulds Two Plate Mould
Injection Moulds
A two plate mould is the simplest type of mould. It is called a two plate mould
because there is one parting plane, and the mould splits into two halves. The
runner system must be located on this parting plane; thus the part can only be
gated on its perimeter.

Types of Moulds Two Plate Mould
Injection Moulds
Functioning
of two plate
mould

Types of Moulds Three Plate Mould
Injection Moulds
A three plate mould differs from a two plate in that it has two parting planes, and
the mould splits into three sections every time the part is ejected. Since the
mould has two parting planes, the runner system can be located on one, and
the part on the other. Three plate moulds are used because of their flexibility in
gating location. A part can be gated virtually anywhere along its surface.

Injection Moulds
Functioning
of three plate
mould

Injection Moulds
Functioning
of three plate
mould

Injection Moulds
Functioning
of three plate
mould

Types of Moulds Different Types of Mould - Movies
Injection Moulds
Two Plate mould

(Pin ejection)

Injection Moulds
Two Plate mould

(Stripper ejection)

Injection Moulds
Two Plate mould

(Core Side Stripper
ejection)

Injection Moulds
Three Plate mould

(Pin ejection)

Injection Moulds
Stack mould
(Stripper ejection)

Injection Moulds
Shuttle mould
(Pin ejection)

Injection Moulds
Unit mould
(Pin ejection)

Types of Moulds Hot Runner Moulds
Injection Moulds
Hot runner molds are two plate molds with a heated runner system inside one
half of the mold. A hot runner system is divided into two parts: the manifold and
the drops. The manifold has channels that convey the plastic on a single plane,
parallel to the parting line, to a point above the cavity. The drops, situated
perpendicular to the manifold, convey the plastic from the manifold to the part.

Types of Moulds Hot Runner Moulds
Injection Moulds
Hot Runner Mould

Injection Moulds
While Hot Runner Molds are typically more expensive than "Cold Runner"
Hot Runner Mould molds, the cost of the mold can be offset in other ways.
Thermoplastic Hot Runner Molds can reduce costs due to :

•No scraping of the the runner.
•Reducing the cycle time.
•Injection time is reduced due to the shot size being reduced by the elimination
of the runner.
•Improves both part and mold design with flexibility of gating locations, which
provides options for cavity orientation.
•Pressure drops are greatly reduced due to the balanced melt flow as the
temperature is consistent from the machine nozzle to the gate.
•Precise material temperature control is critical to successful Hot Runner
processing.

Types of Moulds Over Moulding
Injection Moulds
Overmoulding is an injection molding process using two separate moulds of
Advanced Moulding which you mould one material over another to create or touch appeal such as a
Technologies handle or knob.
Over molding

Types of Moulds Types of Over Moulding
Injection Moulds
Advanced Moulding
Technologies
•Two color Over Molding
•Two Material Over Molding
•Insert Over Molding

Types of Moulds Over Moulding Technologies
Injection Moulds
Double Injection Molding
Advanced Moulding This process produces a soft feel to the product as well
Technologies as improved impact properties and an increased value.
Two Shot Injection Molding
This process has been used for keycaps and buttons on

telephones and other products for many years. The molded-
in graphics are embedded in the part and will not wear off
with use. Clear sections can be utilized with back lighting for
readability in dim or dark applications.
In Mold Decoration
This application is relatively new to the plastics industry.
Using IMD, multiple colors and graphics can be added in
a single operation.

Types of Moulds Over Moulds
Injection Moulds
Advanced Moulding
Technologies

Injection Moulds
Advanced Moulding
Technologies • Grabs consumer attention - a proven concept to build market share
• Improved feel and appearance
• Provides a soft grip or feel
• Improved ergonomics
• Provides a safe, tactile grip in wet environments
• Eliminates / reduces assembly labor
• Eliminates need for mechanical fasteners and adhesives
• Ease of color match with no secondary painting required
• Improved impact resistance
• Sealing in fluid environment
• Provides high friction surface
• Vibration damping
• Sound absorption

Types of Moulds Gas Injection Moulding
Injection Moulds
The gas injection technique (GIT) is a special injection molding method. After
Advanced Moulding the actual injection molding operation, a permanent cavity is created in the
Technologies molding as a second step by means of an inert compressed gas (nitrogen).
The plastic is pressed against the mold wall by maintaining the gas pressure
during the solidification process, thus defining the external contour of the
component.
Gas Injection Method Blow Out Method
Gas Injection
Technology

Types of Moulds Advantages & Disadvantages - Gas Injection Moulding
Injection Moulds
Advantages
Advanced Moulding
Technologies •Greater design freedom (thick-walled, rod-shaped parts possible)
•High degree of rigidity due to larger closed cross-section profiles
•Reduction of sink marks
•Uniform shrinkage and thus less distortion
•Shorter cycle times as compared to thick-walled compact parts
•With rod-shaped parts weight savings of up to approx. 50%
Disadvantages
•Additional costs for gas, gas pressure system and injection device
•Higher expenditure for quality assurance may be necessary
•Risk of surface faults (e.g. switchover markings)
•Possibly greater startup losses with more complex moldings
•Restrictions in the selection of material and with subsequent material changeovers
•Composite molds more difficult than in the case of conventional injection molding

Types of Moulds Rotational or Roto Moulding
Injection Moulds
Rotational or rotomoulding is an extremely popular and well-used process for
Advanced Moulding producing items that are usually hollow.
Technologies
•Used for very large articles which are usually made in small quantities.
•Items such as children's toys, garden furniture are manufactured by rotational
moulding.
Roto moulding uses PVC in paste ( plastisol ) form which is introduced into the
mould along with any additives such as pigments or finishers. The mould is
closed and then spun both vertically and horizontally and moved into an oven.
As the paste starts to melt and the mould continues rotating, it's flung to the
walls of the mould by centrifugal force where it forms a skin. After a fixed period,
the mould is removed from the oven and allowed to cool carefully to avoid the
product shrinking or warping.
Movie on Roto Moulding

Injection Moulding Injection Moulding Machine
Machine
The injection molding machine converts granular or pelleted raw plastic into final
molded parts via a melt, inject, pack, and cool cycle.
Zones in Injection Moulding Machine

Injection Moulding Plasticizing the Resin
Machine
• The cycle begins with the extruder plasticizing the resin and accumulating it in
Moulding Cycle the forward section of the barrel.
• The heater bands maintain the melt's temperature as the shot it built up.
• The mold is closed.
• The cycle is typically timed so that there is minimal time between the closing
of the mold and the next shot

Injection Moulding Injecting the Resin
Machine
• Once the shot is ready, a valve is opened at the nozzle and the melt is quickly
Moulding Cycle injected into the mold.
• This part of the process only takes a few seconds.
• As the melt enters the cavity, the displaced air is vented out through the holes
for the ejection pins and along the parting line.
• Proper filling of the cavity is dependant on part design as well as good gate
location and design and proper venting.

Injection Moulding Cooling the Part
Machine
This is the longest portion of the molding cycle.
Moulding Cycle
Once the cavity is filled, the part is allowed to cool.
If an accumulator is not used, the extruder continues to push material into the mold
and maintain the proper amount of pressure until the material cools (or "freezes").

Injection Moulding Ejecting the Part
Machine
•Once the part has cooled enough (so that it will hold its shape out of the mold,
Moulding Cycle and the ejection pins won't deform the part), the mold is opened.
•The moving platen has moves backwards and the ejector pins strike the rear
plate (or "ejector plate"), ejecting the part.

Injection Moulding Movie of Moulding Cycle
Machine
Moulding Cycle

Injection Moulding Components of Injection Moulding Machine
Machine
A typical injection molding machine consists of the following major components,
Injection system
Hydraulic system
Mold system
Clamping system
Cooling System
Control system

Injection Moulding Injection Moulding Machine
Machine

Injection Moulding Injection System
Machine
The injection system consists of a hopper, a reciprocating screw and barrel
Injection System assembly, and an injection nozzle, as shown in figure. This system confines and
transports the plastic as it progresses through the feeding, compressing,
degassing, melting, injection, and packing stages.

Injection Moulding Injection System
Machine
Injection System

Injection Moulding Movie of Injection System
Machine
Moulding Cycle

Injection Moulding Components of Injection System
Machine
The Hopper:
Injection System Thermoplastic material is supplied to molders in the form of small pellets. The
hopper on the injection molding machine holds these pellets. The pellets are
gravity-fed from the hopper through the hopper throat into the barrel and screw
assembly.
Granules in Hopper:

Machine
Injection System The Barrel:

The barrel of the injection molding
machine supports the reciprocating
plasticizing screw. It is heated by the
electric heater bands.

Machine
Reciprocating Screw
Injection System
The reciprocating screw is used to compress, melt, and convey the material. The
reciprocating screw consists of three zones:
•the feeding zone
•the compressing (or transition) zone
•the metering zone
•the injection zone

Machine
Reciprocating Screw
Injection System
The injection zone

Machine
The Nozzle
Injection System The nozzle connects the barrel to the sprue
bushing of the mold and forms a seal between
the barrel and the mold.

Injection Moulding Hydraulic System
Machine
The hydraulic system on the injection molding
Hydraulic System machine provides the power to open and close
the mold, build and hold the clamping tonnage,
turn the reciprocating screw, drive the
reciprocating screw, and energize ejector pins
and moving mold cores. A number of hydraulic
components are required to provide this power,
which include pumps, valves, hydraulic motors,
hydraulic fittings, hydraulic tubing, and hydraulic
reservoirs.

Injection Moulding Mould System
Machine
The mold system consists of tie bars, stationary and moving platens, as well as
Mould System molding plates (bases) that house the cavity, sprue and runner systems, ejector
pins, and cooling channels, as shown in figure. The mold is essentially a heat
exchanger in which the molten thermoplastic solidifies to the desired shape and
dimensional details defined by the cavity.

Machine
Mould System

Machine
Mould System

Injection Moulding The delivery system
Machine
The delivery system, which provides passage for the molten plastic from the
Delivery System machine nozzle to the part cavity, generally includes:
•a sprue
•cold slug wells
•a main runner
•branch runners
•gates
The delivery
system design has
a great influence on
the filling pattern
and thus the quality
of the molded part.

Injection Moulding The Delivery System
Machine
Delivery System

Injection Moulding Sprue
Machine
A sprue is a channel through which to transfer molten plastics injected from the
Delivery System injector nozzle into the mold. It is a part of sprue bush, which is a separate part
from the mold
Sprue Gate Sprue Bush

Injection Moulding Runner
Machine
A runner is a channel that guides molten plastics into the cavity of a mold.
Delivery System
Runner System

Injection Moulding Gate
Machine
A gate is an entrance through which molten plastics enters the cavity.
Delivery System

Injection Moulding Functions of Gate
Machine
•Restricts the flow and the direction of molten plastics.
Delivery System
•Simplifies cutting of a runner and moldings to simplify finishing of parts.
•Quickly cools and solidifies to avoid backflow after molten plastics has filled
up in the cavity.
•Generates shear heat by going through the narrow gate, raising the
temperature of molten plastics and improving the filling in the cavity.
•Reduces residual stress, and thus reduces part defect such as warpage.
•As the cooling solidification time is shortened, molding cycle is also
shortened.
•As the gate trace is less, it is possible to complete finishing process in a
short time.

Injection Moulding Sprue Gate
Machine
•The Sprue gate is mainly used for cylindrical parts
Delivery System
Types of Gate •The Parts are balanced and concentric
•Have very good weld-line strength

Injection Moulding Edge Gate
Machine
•The most common gate.
Delivery System
•Put to the side of parts.
Types of Gate
•The gate trace will be left.
•Often used for the structure with more than two cavities.

Injection Moulding Fan Gate
Machine
•Suitable for large and flat plate parts.
Delivery System
•Finishing is difficult and cost is high due to the wide gate.
Types of Gate

Injection Moulding Point Gate
Machine
•Suitable for molding multiple parts.
Delivery System
•The position is relatively flexible.
Types of Gate
•The structure is complicated due to Three Plate method of die

Injection Moulding Ring Gate
Machine
•Suitable for Round Hollow parts.
Delivery System
•The part consistency is more..
Types of Gate
•The Material loss is more.

Injection Moulding Submarine Gate
Machine
•The gate will be automatically cut off during mold opening.
Delivery System
•The position is flexible (front, side, or back of parts).
Types of Gate
•The gate needs to be thought about not to be left inside the cavity.

Injection Moulding Film Gate
Machine
•Suitable for thin plate parts.
Delivery System
•Finishing is difficult and cost is high due to the wide gate.
Types of Gate

Injection Moulding Cold Slug Well
Machine
Cold Slug Wells are are highly desirable in an Injection Mold. The Cold Slug Well
Delivery System provides a small reservoir (well) to trap air, and impurities before they enter the
Types of Gate Runner, Gate and Cavity.
A Cold Slug Well is located above the Sprue Puller Pin. Typically, as the
runner changes from a primary to secondary, and, secondary to tertiary there is
also a cold slug well at each intersection.

Injection Moulding Clamping System
Machine
The clamping system opens and closes the mold, supports and carries the
Clamping System constituent parts of the mold, and generates sufficient force to prevent the mold
from opening. Clamping force can be generated by a mechanical (toggle) lock,
hydraulic lock, or a combination of the two basic types

Injection Moulding Cooling System
Machine
Cooling time is by far the most dominate time consumer in the injection molding
Cooling System cycle. A long cycle time means that the molder must charge more for the same
part. During Product Design we should use thermal analysis capabilities to specify
the cooling design for the tools. The result will be a low cost tool that will run fast
and keep your cost per part as low as possible.

Injection Moulding Types of Cooling System
Machine
Cooling channels or lines
Cooling System
Types of Cooling Most commonly used cooling design.Cooling channels should be
System placed close to the mold cavity surface with equal center distances
in between.

Machine
Baffle cooling
Cooling System
Types of Cooling A baffle is actually a cooling channel drilled perpendicular to a main
System cooling line, with a blade that separates one cooling passage into
two semi-circular channels.
This design is used

for core insert

Machine
Bubbler cooling
Cooling System
Types of Cooling A bubbler is similar to a baffle except that the blade is replaced
System with a small tube.
This design is used

for slender core insert

Machine
Spiral Cooling
Cooling System
Types of Cooling A spiral is similar to a bubbler except that the coolant flow in a
System spiral slots.
This design is used

for long large core
(above 40mm)

Machine
Thermal pins
Cooling System
Types of Cooling A thermal pin is an alternative to baffles and bubblers. It is made of
System copper or sealed cylinder filled with a fluid.
This design is used

for long slender core

Machine
Air Cooling
Cooling System
Types of Cooling Air is blown at the cores from the outside during opening or flows
System through a central hole from inside.
This design is used

for very slender core
(less than 5mm)

Injection Moulding Ejection System
Machine
After the molding solidified and
Ejection System cooled down, it has to be removed
from the mold, however, by
undercuts, adhesion and internal
stress the molding does not fall due
to gravity. Therefore it has to be
separated and removed from the
mold by special means. Ejection
equipment is usually actuated
mechanically by the opening stroke
of the molding machine
The Ejector rod in turn

hits the Ejector plate in
the mold base and it will
move towards the
parting line and to eject
the molded part.

Injection Moulding Methods of Ejection
Machine
The method of ejection has to be adapted to the shape of the molding to prevent
Ejection System damage. In general, mould release is hindered by shrinkage of the part on the
mould cores. Large ejection areas uniformly distributed over the molding are
advised to avoid deformations.
Ejector system is normally in movable mold half, assuming the molding is
connected to the movable side of the mold in initial ejection.
Several ejector systems can be used:

Pin Ejection
Sleeve Ejection
Blades Ejection
Air valve Ejection
Stripper plate Ejection
Threads Ejection

Injection Moulding Ejector Pins
Machine
•Straight, cylindrical pins are most common.
Ejection System
Methods of Ejection •Used where little force is needed.
Ejector Pins Movie of Pin Ejection

Injection Moulding Blade Ejector Pins
Machine
•Used to eject narrow, slender, intricate shaped parts
Ejection System
Methods of Ejection •Avoids deep impression in the molded part during ejection in pin ejector
Blade Ejector Pins Movie of Blade Ejection

Injection Moulding Sleeve Ejection
Machine
Ejector Sleeve is basically an ejector pin with a hole through the center.The hole
Ejection System is used for a core pin to form a portion of the desired part. The core pin touches
Methods of Ejection the part, the other end of the core pin runs through the ejector housing and
terminate near the bottom of the mold base.
Sleeve Ejector Pins Movie of Sleeve Ejection

Injection Moulding Stripper Ejection
Machine
Stripper Plates are used to strip the part off the core steel. The stripper plate is
Ejection System actuated via stripper bolts from the A side of the mold, or by the ejector mechanisms
Methods of Ejection in a variety of ways.
Stripper Plate Movie of Stripper Ejection

Injection Moulding Air Valve Ejection
Machine
Air Poppets are standard components that aid the ejection of a part by using
Ejection System compressed air within the mold. The timing of the actuation of the air is controlled by
Methods of Ejection the controller of the moulding machine.
Air poppets Movie of Air Valve Ejection

Injection Moulding Threads Ejection
Machine
•Used to eject threaded components.
Ejection System
Methods of Ejection •Too costly method but it is the only method
Movie of Collapsible Core Ejection Movie of Rotary Core Ejection

Injection Moulding Control System
Machine
The control system provides consistency and repeatability in machine operation.
Control System It monitors and controls the processing parameters, including the temperature,
pressure, injection speed, screw speed and position, and hydraulic position. The
process control has a direct impact on the final part quality and the economics of
the process.
Moulding Machine Control System

Injection Moulding Control System
Machine
Control System
Onboard External Control System
Internal Control System

Moulding defects Moulding defects and remedies
and remedies
•Problems can occur at all stages in the injection moulding process.The origins of
these problems are often difficult to identify thanks to the complex interrelationship
between the moulded part and the mould.
•Successful troubleshooting should begin at the design stage not on the shop floor
so that mistakes can be identified and remedied before they become critical.As a
part designer it is a very good Idea to be aware of your options in tooling and to
consider those while designing your part.
•For example, have potential gate locations in mind. Try to guess where knit lines
will occur and how different gate locations will affect them.
Areas which are

concentrated during
Product Design to get
a defect free
component

Moulding defects Blush
and remedies
Dull discolored or whitish area on the surface of
the part, usually at the gate.
May also occur where there is a sudden change
in part thickness.
Burn
Discoloration usually black, brown or dark
yellow/brown depending upon severity. Feels
rough and crunchy.
Most often seen in deep, blind ribs where a lot of
air can be forced into a small space.
Cold Flow
Wavy or streaked appearance on part surface.
Looks like a fingerprint or small waves like you
would see on the surface of water.
Low melt temperature, low injection speed or
low injection pressure.

Moulding defects Cold Slug
and remedies
Cold piece of plastic that has been forced into
the part along with the melt.
Add a cold slug well at each intersection in the
runner
Contamination
Foreign particles embedded in the part
Delamination
Separation of plastic surface layer giving a
flaking or onion skin effect.
Due to contaminated resin.

Moulding defects Discolouration
and remedies
Deviation from the original intended color of the
material as compared to the manufacturers color
chip.
Contaminated resin / Overheated resin /
Incorrect regrind ratio / Incorrect color mixing or
blending.
Gloss
Smooth shiny areas on the part surface.
Hard to fill areas.
Jetting
Squiggly line in part pointing to gate. Looks like a
worm in the part.Incorrect gate placement or
size.The gate is positioned in such a manner as to
aim the plastic straight into an open area.The
plastic launches out into the open like a piece of
"silly string" and then stacks up in squiggles.

Moulding defects Knitline
and remedies
A line where the molten polymer flow fronts meet in
the mold. Incomplete adhesion occurs along the knit
line and causes a weak point in the plastic part.
Mould is not preheated to moulding temperature.
Pinpush
Circular or semicircular white stress rings on the side of
the part opposite an ejector pin. May even be raised
circular bumps.
Unpolished core or less draft on core side of component.
Inadequate ejector pins for ejection
Drag
Fine, straight lines scraped in the line of draw.
Cavity Side happens usually from insufficient draft
for the texture.
Core side drag happens usually from inadequate
draft, rough core, or overpacking.

Moulding defects Sink Marks
and remedies
Depressions or dimples in the part that are usually adjacent to thick areas. In clear
parts, bubbles can be seen in thick areas.
As the plastic cools it shrinks. If there is an area that is proportionally thicker than
the rest of the part, then the plastic will shrink more in the thick spot causing it to
collapse inward.
Wall perpendicular to ribs or bosses that don't conform to the 66% rule.
Inconsistent wall thickness. i.e. thick areas adjacent to thin areas.

Moulding defects Warpage
and remedies
The failure to maintain flatness of a plastic part that was intended to be flat.
Distortion from the intended shape of the plastic part.
The underlying cause of most part warpage is the shape of the part itself. The
pattern, shape, and thickness of ribs on the part as they undergo shrinkage have
the greatest effect upon warpage.
Present to some degree in most Injection molded parts but most easily detected
on large flat parts.
Differential mold cooling can get you parts that are flatter. Your best bet is to follow
the 66% rule and minimize rib height.
Flat parts are more susceptible to warpage than curved parts.

Design Consideration Parting Surface
Parting Surface is a line at which the two halves of mould meet and form a seal to
prevent the escape of material. The shape of the component, method of ejection,
etc. largely influence the selection of parting surface.

Design Consideration Avoid round edges along the Parting Line
Parting Surface

Design Consideration Always look for simple tooling solutions
Parting Surface
Design to avoid
side cam moulding
Movie of Side Cam Moulding

Parting Surface
Design to avoid side cam moulding

Parting Surface

Parting Surface

Parting Surface
Extending vent slots over the corner edge

eliminates the need for a side action in the mold

Design Consideration Shrinkage
In the production of plastic components melt is injected into the mold cavity. After
completion of the injection phase and the hold period the molding is cooled down
to the temperature for removal from the mold during the cooling period. Due to
physical factors, the plastic component undergoes a dimensional change during
the cooling process that is specific to the material used. This dimensional change
is called shrinkage.

Design Consideration Effects of Shrinkage in design
Shrinkage Wall thickness differences may lead to varying shrinkage behavior that is weaker
or stronger depending on the plastic used. In the case of semi-crystalline
materials, a large wall thickness results in slower cooling, which then leads to
greater shrinkage. The resulting shrinkage differences in the molding lead to
internal stresses in the molding, which are either absorbed through the inherent
rigidity of the structure or reduced through special processing conditions.
Distortions due to differences in basic

rib wall thickness Distortion in non-reinforced components

Design Consideration Effects of Shrinkage in design
Shrinkage
Incorrect
Correct

Design Consideration Draft
The purpose of draft is to first provide release from the cavity side of the mold
upon tool opening. Then upon ejection, draft allows instant release of the plastic
part without dragging. If plastic parts have completely vertical walls, drag marks
will occur on the plastic as it scrapes along the metal tool face. If money is no
object vertical faces may be obtained however with the use of slides and lifters
stuck
Without Draft
free
With Draft

Design Consideration Where should you give Draft ?
Draft The answer is it should start from parting surface.
Draft must fall away from the parting lines on ALL vertical faces in the plastic part.
The widest point on the part is thus the parting line. The location of parting line and
subsequent application of draft to the plastic part are design decisions that affect
both the aesthetics and functionality of the part. These decisions should be made
before the part is sent to the mold maker if time to market is critical.

Design Consideration What is the correct draft angle?
Draft The answer is it should start from parting surface.
Draft must fall away from the parting lines on ALL vertical faces in the plastic part.
The widest point on the part is thus the parting line. The location of parting line and
subsequent application of draft to the plastic part are design decisions that affect
both the aesthetics and functionality of the part. These decisions should be made
before the part is sent to the mold maker if time to market is critical.
Industrial 0.0 degree:

Very small details under 0.040in tall that will get polished. The act of polishing will
designers want
apply some draft. Faces to be 100% relieved with side actions.
0.0 degrees,
1/4 degree:
mold designers Emergency use only. Deep ribs, one internal side of a box where the other sides
want 45.0 have good draft, bosses ejected by sleeves.
degrees…. Use 1/2 degree:
the adjacent Use sparingly and for good reason. Ribs, one internal side of a box, snaps, hooks,
write up as a etc..
guide. 1.0 degree:
Standard draft, all features.
2.0 degree:
Standard draft, very light texture, cavity side to ensure good release.
3.0 degree:
Textured faces, faces that are in common with a shutoff.

Design Consideration Draft to Assembly Parts
Draft Point to remember
Part mismatch due to

improper draft

Design Consideration Importance of draft to the CAD model
Draft -The failure to apply draft to a CAD file before sending it to the mold maker forces
the mold designer to guess about what the part designer intended. Frequently the
mold designer does not even know what your part is.
-Time is consumed by someone unfamiliar with your parts applying draft arbitrarily
without knowledge of your mating parts, sheet metal or components.
-Frequently your mold designer is using a different CAD package and if he sends
back a drafted model, it may be difficult for you to do a good interference analysis.
Designers who
can't draft your -Many toolers will simply slap some draft on and if the parts don't fit, its your
parts you are problem.
costing your
company time -When the mold is finished and your parts don't fit, time is lost reworking the tool.
and money and
should get a job
doing something
that you CAN do.
Once you understand the basics of draft and shutoffs it is very simple to apply
these to your model and save time to market. If you still have questions, get
the Mold Designer to review your parts before tooling release.

Design Guidelines Design Guidelines
1. Use uniform wall thickness throughout the part.
This will minimize sinking, warping, residual stresses, and improve mold fill and
cycle times.
2.Use generous radius at all corners.
The inside corner radius should be a minimum of one material thickness.
Much is written 3.Use the least thickness compliant with the process, material, or product
regarding design design requirements.
guidelines in
latter slides. Using the least wall thickness for the process ensures rapid cooling, short cycle
Yet, the design times, and minimum shot weight. All these result in the least possible part cost.
guidelines can 4.Use ribs or gussets to improve part stiffness in bending.
be summed up in
just a few design This avoids the use of thick section to achieve the same, thereby saving on part
rules. weight, material costs, and cycle time costs.
5.Design parts to facilitate easy withdrawal from the mold by providing
draft (taper) in the direction of mold opening or closing.

Design Guidelines Wall thickness
The typical plastic part may be considered to have a shell type configuration with
a basic surface and features which are attached to it to meet functional
requirements.
The actual determination of the wall thickness is

based on a number of considerations.
From a cost 1.Application Requirements

standpoint, the
thinnest wall Structural requirements including
utilizes the least strength, impact, fatigue or deflection.
material and 2. Moldability
results in the
fastest molding The size of the part and the ability of the
cycles material to fill the furthest point can
determine the minimum wall

Design Guidelines Influence of wall thickness
Wall thickness •Part characteristics
•Mechanical performance
•Cosmetic appearance
•Mouldability
•Economy
Giving wall thickness should be carefully considered in the design stage to avoid
expansive mold modifications and molding problems in productions
The optimum thickness is often a balance between opposing

tendencies, like:
Strength Vs Weight
Durability Vs Cost

Design Guidelines Avoid designs with thin areas
surrounded by thick perimeter
Wall thickness
sections as they are prone to
gas entrapment problems
Maintain uniform nominal wall

thickness through out the part

Design Guidelines Avoid sudden wall thickness variation that result in filling from thin to
thick sections:
Wall thickness

Design Guidelines Core or redesign thick areas to create a more uniform wall thickness
Wall thickness

Design Guidelines Wall Thickness Design for Stiffness:
Wall thickness Corrugation
Corrugations can add stiffness to

non cosmetic parts
Curved Side Walls

Adding curvature to the sidewalls
enhances stiffness and appearance

Design Guidelines Wall Thickness Design for Stiffness:
Wall thickness Flexible
Stiffer

Design Guidelines Radius
Sharp corners greatly increase the stress concentration. This high amount of
Radius
stress concentration can often lead to failure of plastic parts.
High molded in stresses

Poor flow characteristics
Reduced mechanical properties
Increased tool wear
Surface appearance problems, (especially with blends).
Crack due to Stress
Uniform cooling
Less warpage
Less flow resistance
Easier filling
Lower stress concentration
Less notch sensitivity.
No Crack due to Radius

Design Guidelines What radius should you give?
Standard tables for stress concentration factors are available and should be
Radius
consulted for critical applications.
As can be seen from the above chart, the stress concentration factor is quite
high for R/T values less than 0.5. For values of R/T over 0.5 the stress
concentration factor gets lower.

Design Guidelines Radius should be
•Radius should be between 50% of the nominal wall thickness.
Radius
•If the part has a load bearing function then the upper end is recommended.
•A minimum radius of 0.5mm is suggested and all sharp corners should be broken
with at least a 0.125 mm radius.

Design Guidelines Internal and external radii should originate from the same point
Radius

Design Guidelines Ribs
Ribs increase the bending stiffness of a part. Without ribs, the thickness has to be
Ribs
increased to increase the bending stiffness. Adding ribs increases the moment of
inertia, which increases the bending stiffness.
Functions of Ribs
1. The rib gives stiffness and strength in molded part
without increasing overall wall thickness.
2. Locating and captivating components of an assembly.
3. Providing alignment in matting parts.
4. Acting as stops or guide for mechanisms

Design Guidelines Rib design issues
Ribs •Thickness
•Height
•Location
•Quantity
•Moldability
Consider these issues carefully when designing ribs
Proper Rib
Design reduces
the defects

Design Guidelines Rib thickness
Ribs Many factors go into determining the appropriate rib thickness. Because thick
ribs often cause sink and cosmetic problems on the opposite surface of the wall.
If rib thickness is a constraint

but not the cosmetic
Offset Rib to reduce Sink

Design Guidelines If rib thickness is a not a constraint but cosmetic
Ribs 1. The rib thickness should be less than the wall thickness
2. The thickness ranges from 40 to 60 % of the material thickness as per 66% rule
3. The rib should be attached to the base with .125 X thickness radius at the
corners and .5 degree draft should be given for ejection,

Design Guidelines What is the 66% rule ?
Ribs The divine 66% rule for ribs
The thickness of ribs should never exceed 66% of the nominal wall thickness.
If your ribs never exceed 50-66% of nominal wall thickness you will
never have a problem with sink.
Sometimes you can get away with 66% to 75%

of nominal wall, but it is risky. Don't do it unless
you absolutely have to. If you do, be certain
that the area gets better than average plastic
flow.

Design Guidelines What happens if you ignore the 66% rule ?
Ribs

Design Guidelines Rib height
Ribs Maximum rib height should not exceed 3 times the nominal wall thickness as
deep ribs become difficult to fill and may stick in the mold during ejection.

Design Guidelines Effect of 1/8 rib on 1/4 thickness part
Ribs

Design Guidelines Rib location
Ribs The rib location is based on providing maximum bending stiffness. Depending
on orientation of the bending load, with respect to the part geometry, ribs
oriented one way increase stiffness. If oriented the wrong way there is no
increase in stiffness.

Design Guidelines Rib location
Ribs Another issue to be considered
If air is trapped, it will compress and create a burn mark on the rib, which probably
won’t fill anyway.
The best solution is to try to locate your ribs into the side walls or other features to
help convey the plastic and air through the part.
Another solution is to transition to a projection from the base wall with a gusset or
ramped rib.
Rib A will trap air in the top corner

Rib B has a better transition to the
base wall.
Rib C is the best since it's tied into
the side wall.

Design Guidelines Rib quantity
Ribs
Multiple Ribs are better than one thick rib or one tall rib

Design Guidelines Rib mouldability
Ribs Ribs are preferably designed parallel to the melt flow as flow across ribs can
result in a branched flow leading to trapped gas or hesitation. Hesitation can
increase internal stresses and short shots.
Fl ow
Position ribs in l d
Mo
the line of flow to
improve filling
and prevent air
entrapment.

Design Guidelines Rib design for stiffness
Ribs

Design Guidelines Now you know the standards of rib designing. Implement it with
the help of these steps for better results.
Ribs

Design Guidelines Holes
Holes also are a major design element, The location of any holes may
Holes
significantly affect the part's overall strength. Trying to create a hole in the side
of a part is especially challenging, and the need for side holes should be
minimized in the initial design.
The functions of the holes
1. The holes are given in molded parts to accommodate rivets or pins.
2. Locating and captivating components of an assembly.
3. Providing alignment in matting parts.

Design Guidelines Hole spacing
The minimum spacing between two
Holes
holes or between a hole and side wall
should be one diameter.
Hole location
Holes should be located three
diameter or more from the edge of the
part to avoid excessive stress.

Design Guidelines Blind holes
Holes The depth of a blind hole should not exceed 3 times the diameter. For
diameters less than 5 mm this ratio should be reduced to 2.
Core pins supported by just one side of the mold tool create blind holes. The
length of the pins, and therefore the depth of the holes, are limited by the ability of
the core pin to withstand any deflection imposed on it by the melt during the
injection phase.

Design Guidelines Blind holes
Holes For blind holes the thickness of the bottom should be greater than 20% of the
hole diameter in order to eliminate surface defects on the opposite surface. A
better design is to ensure the wall thickness remains uniform and there are no
sharp corners where stress concentrations can occur.

Design Guidelines Through holes
Holes With through holes the cores can be longer as the opposite side of the mold
cavity can support them.For through holes the length of a given size core can
be twice that of a blind hole.

Holes An alternative is to use a split core fixed in both halves of the mold that have a
gap equal to wall thickness.

Holes Another alternative is to use a split core fixed in both halves of the mold that
interlock when the mold is closed.

Holes In cases where even longer cores are required, careful tool design is necessary
to ensure balanced pressure distribution on the core during filling to limit
deflection. Doing this the core mismatch can be reduced
Incorrect Correct

Design Guidelines Bosses
Boss Bosses are used for the purpose of registration of mating parts or for attaching
fasteners such as screws or accepting threaded inserts (molded-in, press-fitted,
ultrasonically or thermally inserted).

Design Guidelines The divine 66% rule for bosses
Boss The thickness of boss wall should never exceed 66% of the nominal wall thickness
Ideal Design
Bad Design

Design Guidelines Boss design standards
Boss Nominal boss wall thickness less than 66% nominal wall thickness,

Boss The boss height should be 3 times of the wall thickness.

Boss The outer diameter should be within 2 to 2.4 times of internal diameter

Boss A minimum radius of 25% the nominal wall thickness or 0.4 mm at the base of
the boss is recommended to reduce stresses.

Boss The core pin should be given a radius (min 0.25 mm) to reduce material
turbulence during filling and to help keep stresses to a minimum.

Boss A minimum draft of 0.5 degrees is required on the outside dimension and inside
also (if required) of the boss to ensure release from the mold on ejection.

Boss Greater wall sections for increased strength will increase molded-in stresses
and result in sink marks. So use this method.
A recess around the base of a thick boss reduces sink.

Boss Bosses located at corners can result in very thick walls causing sinks. Bosses
can be isolated using the techniques illustrated.

Boss Alternative boss design can be used for bosses near a standing wall.

Design Guidelines Strengthening a Boss
Boss The boss can be strengthened by gussets at the base

Design Guidelines Strengthening a Boss
Boss The boss can be strengthened by attaching it to nearby walls with connecting ribs.

Design Guidelines Rib design
Boss Avoid bosses that merge into side walls by connecting ribs for support.

Design Guidelines Rib design
Boss A minimum distance of twice the nominal wall thickness should be used for
determining the spacing between bosses. If placed too close together thin areas
that are hard to cool will be created. These will in turn affect quality and
productivity..

Design Guidelines Failure of boss
Boss Failures of a boss are usually attributable to:
1. Knit lines -these are cold lines of flow meeting at the boss from opposite sides,
causing weak bonds. These can split easily when stress is applied.
Knit lines should be relocated away from the boss, if possible. If not possible,
then a supporting gusset should be added near the knit line.

Design Guidelines Failure of boss
Boss Failures of a boss are usually attributable to:
2. High hoop stresses caused because of too much interference of the internal
diameter with the insert (or screw).
Hoop stresses are imposed on the boss walls by press fitting or otherwise inserting inserts.

Design Guidelines Mating of bosses
Boss Excessively long bosses can often be replaced by two shorter bosses

Design Guidelines Gussets
Gussets Gussets can be considered as a subset of ribs and the guidelines that apply to
ribs are also valid for gussets. This type of support is used to reinforce corners,
side walls, and bosses.
The height of the gusset can be up to 95% of the height of the boss or rib it is
attached to.
Depending on the height of the rib being supported gussets may be more than 4
times the nominal wall thickness.
Gusset base length is typically twice the nominal wall thickness.
These values optimize the effectiveness of the gusset and the ease of molding and
ejecting the part.

Design Guidelines Gusset design
Gussets Avoid sharp corners in your gusset design.

Design Guidelines Design for Manufacturability and Assembly (DFM/A)
DFM/A Design for Manufacturability and Assembly (DFM/A) is a very broad topic covering
many areas. Regardless, it can best be defined as any tool or process that helps a
designer or engineer think about, and therefore avoid, manufacturing and
assembly problems down the road.
The design of plastic parts is good discipline for the application of DFM/A
principles because designers must be in tune with all the factors that can cause a
flawed design

Design Guidelines Design for ease of assembly
DFM/A Simplify design and assembly so that the assembly process is unambiguous.

Design Guidelines Assembly alignment
DFM/A Simplify design and assembly that can be easily aligned.

Design Guidelines Poka Yoke (Fail Proof design)
DFM/A Components should be designed so that they can only be assembled in one way;
they cannot be reversed. Roll pins, dowel pins or offset mounting holes can be
employed.

Design Guidelines Design for orientation
DFM/A Design for components orientation and handling to minimize non-value-added
manual effort, ambiguity or difficulty in orienting and merging parts. Basic principles
to facilitate parts handling and orienting are:
•Parts must be designed to consistently orient themselves. Examples are dowel pins.
•Product design must avoid parts that can become tangled, wedged or disoriented.
•With hidden features that require a particular orientation, provide an external
feature, guide surface or design alignment fixturing or tooling to correctly orient the
part.
•Design in fasteners large enough that are easy to handle and install

Design Guidelines Design Lettering for assembly
DFM/A Base assembly component should have some sort of visual indicatives like
lettering or embossing to show where other parts is to be assembled.

Design Guidelines Design for efficient joining and fastening
DFM/A Threaded fasteners (screws, bolts, nuts and washers) can be time-consuming to
assemble. Consider design alternatives that will reduce fastener count.
Snap fits are very useful because they eliminate screws, clips, adhesives, or
other joining methods. The snaps are molded into the product, so additional
parts are not needed to join them together.

Design Guidelines Snap fit assembly
DFM/A Use of snap-fit assemblies can deliver many benefits:
Snap design
•An integral element of the plastic part – no other components
•Can replace screws, nuts, and washers
•Easy automation can reduce assembly costs
•No other fasteners, adhesives, solvents, welding, or special equipment
•Design can minimize risk of improper assembly
•Can be designed to engage and disengage
Things To Be Aware of When Using Snap-Fits:
•Some designs may require more complex or expensive tooling

•Snap-fits that are assembled under stress will creep
•It is difficult to design snap-fits with hermetic seals. If the beam or ledge relaxes,
it could decrease the effectiveness of the seal.
•Can be damaged by mishandling and abuse prior to assembly

Design Guidelines Types of Snap fits
DFM/A
Snap design
Annular Snap Fit
An annular snap is defined as involving a locator pair or the entire mating part-base
part system they will constrain in more then one degree of motion.

DFM/A
Snap design
Cantilever Snap Fit
The Cantilever Snap design is the most popular when assembling two plastic parts.
A cantilever beam snap-fit assembly consists of a cantilever beam with an overhang
at the end of the beam.

DFM/A
Snap design
Torsional Snap Fit
A Torsional snap fit involves primarily torsional deflection for assembly although
there is often some bending in the system as well. The torsional member is not
necessarily round; they can be round or flat. A torsional snap fit is relatively
uncommon but are useful as an alternative to the cantilever, the most used snap-fit,
when clearances or access make the hook location for assembly difficult.

Building
a New Electric World

Moulds Design

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Awareness on Plastics &Moulds

H & GT - GTCI - Bangalore - July 2005 2

> Mould Manufacturing

> Advanced Moulding Technology

> Injection Moulding Machine

> Moulding defects and remedies

> Design Considerations

> Design Guidelines

> Design for Manufacturing and Assembly Guidelines

H & GT - GTCI - Bangalore - July 2005 3

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Materials for moulding:

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It can be electrically insulated,

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It can withstand extremes of

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It can absorb vibration and noise and act

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It has friction properties similar to human

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It is compatible with other

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Plastics Thermoplastics and Thermosets

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• Excellent chemical resistance

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• Good weather resistance

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• Excellent abrasion resistance

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• Low coefficient of friction.

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BMC or Dough Moulding Compound

BMC Manufacturing Machine

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