Plastic Part Design Introduction

Course details

The intensive course provides an overview of the way in which the design of plastic products is influenced by the specific properties of plastics materials and the manner by which these products are made. It shows how, through a knowledge of material and machine behaviour, a designer can incorporate into the product features which make it economic, practical and new.

WHO SHOULD ATTEND:

Plastic part and mould designers, R&D engineers, or any plastic processing technical staff wishing to update their understanding of plastic part design.

Background and History

The course will also cover relevant aspects of the design of shaping tools for plastic manufacture and investigate the potential problems and pitfalls which can be avoided by good design. There will be ample opportunity for discussion on both general principles and on specific designs.

Day 1

• Polymer Factors Influencing Design

(Inc: Polymer thermal use application ranges, polymer wall section flow ratio restrictions, polymer shrinkage ranges, component stressing, cooling time estimation and new product costing , processing energy / carbon footprint, recyclability, etc)

• Polymer material properties and the use of a selection matrix.
• Constructing a polymer design requirement specification

(Inc: Mechanical property requirement, thermal use range, environmental influences, sustainability influences, ergonomic and aesthetic considerations)

• Influence of shaping methods upon product design

Injection moulding – Properties of injection moulded products, influence of flow balance, gate location, ejection retention, product designing for effective cooling, parting line recognition, etc.

• Exercise: Designing and Injection moulded component

Day 2

• Compression moulding – Properties of compression moulded products, designing for balanced cure / even thermal history, product release,
• Blow moulding – Properties of blow moulded products, stretch blow-up ratio, extrusion blow-up ratio, product design and use applications,
• Extrusion – properties of extruded products, product design criteria, shape, sizing, etc.
• Vacuum forming – properties of vacuum formed products, wall section drawing, design applications, etc.
• Exercise: Designing a vacuum formed or blow moulded component.
• Polymer Product Design Theory

(Inc: Wall section changes, melt accumulation, stress raisers, wall thickness issues, base design, sidewall design, profile design, rim features, ribbing, intersections, coring, boss design, etc)

Day 3

• Polymer mechanics, inc, wall section loading, creep, examples of structural mechanical calculations.
• Polymer project management

Inc: Costing, Product development feedback loops and flow diagrams.

• Polymer Product Prototyping Inc:

1. Prototype tooling, construction materials and techniques.
2. Component prototyping techniques, inc, SL, SGC, FDM, SLS, LOM, etc.

• Polymer Product Assembly & Finishing Techniques

Inc: Inserts, hot plate welding, vibration welding, ultrasonic welding, painting, foiling, plating, colouring, etc.

Day 4

• Practical Design Session (Metal product design to polymer conversion)
• Critical Appraisal of Polymer Products

(Inc: First off inspection, fault identification and rectification).

• Explanation of polymer component design defects, identification and explanation of material defects and processing faults.
• Design case study sessions – Attendees are encouraged to bring existing projects to these sessions. Topics include, material specification and selection, warping and component distortion, effect of poor cavity filling and pressure control, etc.

The 4-day course assumes no prior knowledge and is suitable for those new to the subject. The course would also benefit those who wish to extend their existing knowledge of plastic product design or who are working in a polymer product design related area.

Upon completion of the course a candidate will be able to:

• Construct a basic polymer product design specification
• Design a basic polymer product from first principles
• Understand the influence of polymer processing upon product design and final properties
• Understand the influence of specific polymer properties upon product design
• Undertake basic quality appraisal of new polymer products
• Differentiate between a polymer processing, tool design or product design defect