Plastic Product Design
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Plastic Product Design. SARATH BABU MADDUKURI. Over View of Plastic Product Design Polymer Fundamentals Plastic Product Design Steps Plastic Material Selection Process Plastic Product Design Guidelines Plastic Manufacturing Process Basics of Injection Mold. Index.

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Plastic Product Design

SARATH BABU MADDUKURI


Over View of Plastic Product Design

Polymer Fundamentals

Plastic Product Design Steps

Plastic Material Selection Process

Plastic Product Design Guidelines

Plastic Manufacturing Process

Basics of Injection Mold

Index


Product Design Environment


Product Design & Development Steps

  • End Use Requirement

  • a) Anticipated Structural Requirement

  • Loads- Stresses a material will be subjected

  • Rate of Loading

  • Duration of Loading

  • Impact Forces

  • Vibration

  • Foreseeable Misuse

  • b) Anticipated Environment

  • Temp Extremes

  • c) Assembly and Secondary Operation

  • d) Cost Limits

  • e) Regulation Standards compliances


Product Design & Development Steps

  • Establish Preliminary Design( Preliminary Concept Sketch and Sections)

  • Select the material( Expected End Use Requirement, Material Data Sheets)

  • a) Mechanical Properties used for essential component design calculations

  • b) Other Relevant Properties

  • 3Modify Design as per the calculations results and desired function

    • a) Specific property balance of selected grade

    • b) Processing Limitation

    • c) Assembly Method

    • d) Cost of Modification


Product Design & Development Steps

  • CAD/CAE

    • Flow Analysis

    • Stress Analysis

  • 5Prototype and Testing

  • 6End Use Testing


Polymer Fundamentals


Polymer Fundamentals


Polymer Fundamentals


INTRODUCTION

  • Plastics were considered as “Replacing Materials”

  • Today’s world plastics are unreplacable materials on the same level as the classic materials:

  • Primarily due to special combination of properties (profiles & material combinations)

  • Plastics offers solutions, that are not possible with classic materials (Electronics, Medical care, Automotive industries etc.)

  • Low weight, allows high accelerations & decelerations.

  • Weather resistance (Corrosion) is better than resistance of metallic materials.

  • Good Electrical Isolation properties (Housings of Electrical devices)

  • Low manufacturing costs, especially with injection moulding technology.


MATERIALS

Metals

(as Ores)

High-Molecular

(Makromolecular)

materails

Inorganic

e.g. Glasses

Organic

Natural

e.g. Wood

Synthetic resp.

Modified material

Thermoplastics

Thermosets

Elastomers

Crosslinkable

(vulcanisible)

elastomers

Crosslinked:rubber

Thermoplastic

elastomers

PLASTICS

CLASSIFICATION :


Thermoplastics :

  • They are thread-like molecules (Linear & Branched)

  • They are always Deformable – Fusible – Soluble.

  • As degree of polymerisation (molecule length) increases strength & toughness increases, but flowability decreases.

  • They are further classified as

  • Amorphous thermoplastics &

  • Crystalline (Partially crystalline) thermoplastics


Amorphous Thermoplastics:

  • Bulky thread-like molecules, with unarranged interconnected macromolecular structures, similar to that of staples in a cotton pad.

  • Transparent (Exception) : Styrol – copolymers with Butatein like ABS.

  • Lower degree of Shrinkage & high precision can be achieved with less cost.

  • High elastic properties between melt & freezing (Glass transition) temperature makes it to be produced at low holding pressure to avoid demoulding problems & high internal stress.

  • They are more sensitive against solvents & the parts are more suspectable to stress cracking.

Examples:

Polycarbonate (PC) , Polyvinylchloride (PVC), Acrylonitrile – Butadiene – Styrene – Copolymer (ABS), etc.


Acrylonitrile – Butadiene – Styrene – Copolymer (ABS) :

  • Structure : amorphous Density : 1,03 – 1,07 g/cm³ Elastic-Modulus : ~ 2400 N/mm²

  • Properties :

  • High rigidity & toughness also at low temperature to – 40º C,

  • High Scratch resistance, High impact resistance, High suspectability to stress cracking

  • Temperature limits:

  • Short-Term ~ 100°C, Long Term ~ 85°C

  • Surface Quality :

  • High gloss surface can be achieved.

  • Natural colour: opaque, non-transperant

  • Manufacturing related properties :

  • Low shrinkage & low tendency to wrap,

  • Good Paintability & electroplatability.

  • Applications :

  • Automotive panels - (Interior & Exterior parts), etc.


Acrylonitrile – Butadiene – Styrene – Copolymer (ABS) : Applications


Polycarbonate (PC) :

  • Structure : amorphous Density : 1,20 – 1,24 g/cm³ Elastic-Modulus : ~ 2200 N/mm²

  • Properties :

  • High strength & Hardness, Toughness at low temperature.

  • High impact resistance, High suspectability to stress cracking

  • Temperature limits:

  • Short-Term ~ 135°C, Long Term ~ 100°C

  • Surface Quality :

  • High gloss surface can be achieved.

  • Natural colour: Transperant

  • Manufacturing related properties :

  • Low shrinkage & low tendency to wrap,

  • Good Paintability & electroplatability.

  • Applications :

  • Automotive panels - (Interior & Exterior parts), Headlights, Helmets, etc.


Polycarbonate (PC) : Applications


Polyvinylchloride (PVC) :

  • Structure : amorphous Density : 1,38 – 1,55 g/cm³ Elastic-Modulus : ~ 3000 N/mm²

  • Properties :

  • High hardness & stiffness.

  • High impact resistance at low temperature till -5°C, below this brittleness increases.

  • High suspectability to notch failure.

  • Temperature limits:

  • Short-Term ~ 70°C, Long Term ~ 60°C

  • Surface Quality :

  • High gloss surface can be achieved.

  • Natural colour: Transperant till Opaque

  • Manufacturing related properties :

  • Low shrinkage

  • High chemical resistance

  • Applications :

  • Ducts, Ventilation Channels, tubes, etc.


Polyvinylchloride (PVC) : Applications


Crystalline Thermoplastics:

  • Bulky thread-like slim molecules, which are alligned or with each other.

  • Non transparent (translucent), naturally coloured good slip properties.

  • Higher degree of Shrinkage due to higher package of molecules.

  • Are less compressible than amorphous during hardening & freezing temperatures, hardly faces any demoulding problems.

  • Due to higher shrinkage may form voids during cooling.

Examples:

Polyethylene (PE), Polypropylene (PP), Polyamide (PA), Polyacetal (POM) etc.


Polyethylene (PE) :

  • Structure : Semi crystalline Density : 0.91 – 0.96 g/cm³ Elastic-Modulus : ~ 1200 N/mm²

  • Properties :

  • High stiffness & Hardness. Good elastic properties.

  • Practically unbreakable, ductile till -60°C

  • Temperature limits:

  • Short-Term ~ 135°C, Long Term ~ 80°C

  • Surface Quality :

  • High gloss surface can be achieved.

  • Natural colour: milky white

  • Manufacturing related properties :

  • No water absorption, High Shrinkage & tendency to warpage

  • High chemical resistance

  • Applications :

  • HR inserts, Ducts, Channels, etc.


Polyethylene (PE) : Applications


Polypropylene (PP) :

  • Structure : Semi crystalline Density : 0.90 – 0.92 g/cm³ Elastic-Modulus : ~ 1450 N/mm²

  • Properties :

  • High stiffness & Hardness. Stability higher than PE.

  • High flexural fatigue strength. Low impact strength at low temperature.

  • Temperature limits:

  • Short-Term ~ 140°C, Long Term ~ 100°C

  • Surface Quality :

  • High gloss surface can be achieved.

  • Natural colour: Colourless shining through

  • Manufacturing related properties :

  • No water absorption, High Shrinkage & tendency to warpage

  • High chemical resistance

  • Applications :

  • Car – Coverparts (Interior & Exteriors), etc.


Polypropylene (PP) : Applications


Polyamide (PA) :

  • Structure : Semi crystalline Density : 1.02 – 1.15 g/cm³ Elastic-Modulus : ~ 1300 - 2800 N/mm²

  • Properties :

  • High stiffness & impact strength.

  • Good friction & wear resistance

  • Temperature limits:

  • Short-Term ~ 170°C, Long Term ~ 110°C

  • Surface Quality :

  • High gloss surface can be achieved.

  • Natural colour: Translucent white-yellow

  • Manufacturing related properties :

  • Good flow properties & chemical resistance,

  • Not so good shrinkage. Tendency to warpage.

  • Applications :

  • Car – (Inner, Outer), Bearings, Gear wheels, etc.


Polyamide (PA) : Applications


Thermosets :

They are closely crosslinked, that is the reason they are non – thermoplastic.

They are always Non - deformable – Infusible – Insoluble.

Examples:

Epoxy (EP), Phenol-formaldehyde (PF), etc.


Elastomeres:

They are loosely crosslinked, highly elastic & show very low plastic deformation.

They are highly deformable –Insoluble.

Examples:

Natural Rubber (NR), Ethylen-Propylen rubber (EOM, EPDM), etc.


Design Guidelines

REQUIREMENT

(For what ?, strength, assy)

MATERIAL SELECTION

(Cost , Manuf Prosess,Temp conds, Strength, Safety)

PACKAGING DATA & KINEMATICS

( From customer)

DECIDING SNAP & SCREW FIXING LOCATIONS

(Locking 6 deg. Of freedom, DFA )

FIX TOOLING DIRECTION

(Die-Draw direction, Minimum silder’s and aesthetic requirement )

(Packaging data,

strength requirement)

DECIDING STRENGTHING RIBS,LOCATIONS & GEOMETRY

DRAFT ANGLES,RIBS WALL THICKNESS RATIO

(As per design guidelines)


Design Guidelines

( Minimum core thickness, Slider ejection space, Sharp corners etc.)

TOOLING FEASIBILITY

DRAFT ANALYSIS A & B SURFACES

SECTIONS WITH PACKAGING THROUGH SNAP & RIBS

( Tolerance issues)


Design Guidelines

Material Selection:

The wide variety of injection moldable thermoplastics often makes material selection a difficult task.

Factors governing material selection

  • Cost

  • Functionality

  • Assembly (Typically when bonded)

  • Temperature

  • Strength

  • Government Regulations.

  • Surface finish/aesthetic etc.


Design Guidelines

Wall thickness/ Base thickness:

Proper wall thickness determines success or demise of a product. Like metals injection molded plastics also have normal working ranges of wall thickness. This can be taken into consideration while deciding wall thickness.

Factors to be considered while deciding wall thickness.

  • Structural strength of the part to be designed plays important role in deciding wall thickness.

  • Normal working ranges of wall from chart for particular material selected.

  • As a thumb rule 2.5mm.

  • Prior experience or bench mark parts can also be referred while deciding on wall thickness.


Design Guidelines

Wall thickness/ Base thickness:

Once nominal wall thickness is decided, following are some design rules which should be followed.

  • Maintain uniform wall thickness wherever possible which helps in material flow in mold, reduces risk of sink marks, Induced stresses & consideration of different shrinkage

  • For non-uniform wall thickness change in thickness should not exceed 15% of nominal thickness & should transition gradually.

  • At corner areas minimum fillet at inner side should be 50% of wall thickness.


Design Guidelines

Core-Cavity-Slider directions & Parting lines :

  • It is always recommended first to decide upon the core-cavity direction. Generally core-cavity direction & parting line depends upon following parameters

  • The shape & function of the component. Shape in turn is governed by A- Surface, packaging/environment data.

  • Core-cavity & slider directions should be considered such that they do not appear on A-Surfaces, unless otherwise specified & accepted by the customer.


Design Guidelines

Draft Angles (On component walls):

Draft is necessary for ejection of part from the mold & are always Tooling (Die-Draw) & Slider direction.

Recommended draft angle is minimum 1deg.

Factors governing draft angle.

  • Surface finish – Highly polished mold requires less draft than an unpolished mold.

  • Surface Texture (Graining) – Draft increases with texture depth,normally 1 deg draft for every 0.025mm depth recommended.

  • Draw depth – To keep the draft angle to minimum as thumb rule draft angle – draw depth charts are followed & often design engineer should discuss with tool maker.


Design Guidelines

Ribs :

Ribs should be used when needed for stiffness & strength or to assist in filling difficult areas.

For structural parts where sink marks are no concerns -Rib base thickness can be 75%-80% of adjoining wall thickness

For appearance parts where sink marks are objectionable: With texture (Graining) - Rib base thickness should not exceed 50% of adjoining wall thickness for part. Without texture (Graining) - Rib base thickness should not exceed 30% of adjoining wall thickness.

Some important points to consider while rib design.

  • Draft angle on ribs should be minimum 0.5 deg per side

  • Rib height should be 2.5 to 3 times of wall thickness for effective strength. Recommended to add multiple ribs instead of single large rib, Spacing between multiple ribs should be at least 2 times that of rib thickness.

  • Fillets at base of ribs should be 0.5mm Minimum.


Design Guidelines

Bosses :

Usually designed to accept inserts, self tapping screws, drive pins etc for use in assembling or mounting parts.

Some important points to consider while Boss design:

  • The O.D of the boss should be ideally 2.5 times of screw diameter for self tapping screw applications.

  • If O.D exceeds 50% of adjoining wall thickness, thinner wall boss of O.D 2 times or less of screw diameter can be considered with supported by ribs.

  • Bosses should be attached to walls with ribs. Thickness at base of rib should not exceed 50% of adjoining wall thickness.

  • Boss inside & outside diameters should have 0.5 deg draft per side.


Design Guidelines

Bosses :


Design Guidelines

Coring :

Coring in injection molding terms to addition of steel to mold for the purpose of removing plastic material in that area Coring is necessary to create Pocket or, Opening in the part or to reduce heavily walled section.


Design Guidelines

Openings :

Openings are desired in a part to eliminate sliders, cams, pullers, etc. to accommodate features like snaps. As general thumb rule 5deg angle in the area of mating of core & cavity is required.


Design Guidelines

Assemblies :

Types of assemblies :

  • Molded-in assembly

  • Chemical bonding assembly

  • Thermal welding assembly

  • Assembly with fasteners.

Molded-in Assembly : (Snap fit, Press fit, molded in threads etc.)

This is generally the most economical method of assembly. Assembly is fast, inexpensive & does not require any additional part or substance. Minimizes changes of improper assembly. Some times tooling becomes complex & expensive.


Design Guidelines

Snap fit assembly :


Design Guidelines

Snap fit assembly :

Y = Deflection

Q values to be referred from Material graphs

Important points to remember :

  • Design for given assembly force or overlap length & material.

  • Deflection required to assemble the part should always be less than maximum deflection(strain) for safe design.

  • Snaps increase possibility of sliders wherever possible try to eliminate sliders by providing slot below snap or moving snap to outer edge of the part, if design permits.


Design Guidelines

Press fit assembly :

  • Press fit design is more critical in plastics (Thermoplastics as they creep (Stress or Relax).

  • Good design should minimize stress on the plastic,by considering assembly tolerance between assembled parts & clamping force due to creep relaxation.


Design Guidelines

Adhesive joints assembly :

  • Two similar or dissimilar plastics can be assembled in a strong leak-tight bond by using adhesives.

  • The choice of adhesive depends upon the application & the environment to which the part would be subjected.

  • Some of adhesives are Polyurethanes, Epoxies, Cyanoacrylates, Silicones etc.


Design Guidelines

Bolts –Nuts - Screws :

  • Certain precaution must be taken while designing to reduce excessive compressive stress on the plastic.

  • Larger head screw or larger washer is preferred as that contact area increases & stress reduces.


Design Guidelines

Molded in threads :

  • Coarse threads are preferred due to higher strength & torque limits.

  • Generally 0.8 – 0.9 mm relief should be provided to prevent high stress at the end of the threads.

  • To reduce the stress concentration minimum 0.25mm radius should be applied to the threads roots.

  • External threads should be as far as possible located on parting lines to avoid need of unscrewing mechanism.

  • Internal threads are usually formed by an unscrewing or collapse core.


Design Guidelines

Self Tapping Screws :

Further classified in 2 types Thread cutting & Thread forming

  • Thread cutting screw is most used on brittle plastics such as thermosets & filled (50%) thermoplastics. They should not be reinstalled

  • Thread forming screws is mostly used on thermoplastics. They can be reinstalled for 3 to 5 times.

General Guidelines while using self-tapping fasteners:

Thread engagement length 2.5 times screw diameter

Boss diameter minimum 2 times of pilot hole diameter.

Cored hole should have 0.25 ° to 0.5° draft.

Holes should be counterbored or chamfered to a depth of 0.5mm to aid alignment & avoid cracking of boss.

Sufficient clearance to be kept between screw end & bottom of the hole.


TOLERANCE RANGE TO BE GIVEN ON DWGS:


HOW

SLIDERS & LIFTERS

WORK ?


Molded Part

Undercut

Horn Pin

Slide

SLIDER FOR UNDERCUT :


SLIDER FOR UNDERCUT :


SLIDER FOR UNDERCUT :

Pulled Undercut


SLIDER FOR UNDERCUT :

Cover tool

Molded part

Horn Pin

Locking Block

Undercut

Spring

Slide core


SLIDER FOR UNDERCUT :


SLIDER FOR UNDERCUT :


SLIDER FOR UNDERCUT :


LIFTER FOR UNDERCUT :

Lifter

Undercut

Angled pin


LIFTER FOR UNDERCUT :


LIFTER FOR UNDERCUT :


LIFTER FOR UNDERCUT :

Molded part

Lifter

Undercut

Horn pin

Lose core


LIFTER FOR UNDERCUT :


LIFTER FOR UNDERCUT :


LIFTER FOR UNDERCUT :


HYDRAULIC CYLINDER FOR UNDERCUT :

Core pin

Undercut

Hydraulic Cylinder


HYDRAULIC CYLINDER FOR UNDERCUT :


HYDRAULIC CYLINDER FOR UNDERCUT :


FORCED EJECTION :


FORCED EJECTION :


FORCED EJECTION :


FORCED EJECTION :


FORCED EJECTION :


MULTIPLE UNDERCUTS

Molded Part

Slide

Hydraulic Cylinder


MULTIPLE UNDERCUTS


MULTIPLE UNDERCUTS


MULTIPLE UNDERCUTS


MULTIPLE SLIDERS:

Core Pin

Locking Block

Molded part

Horn Pin

Undercut

Spring

Slide


MULTIPLE SLIDERS:


MULTIPLE SLIDERS:


REFERENCES:

  • Honeywell Injection Moulding Processing Guide (2002).

  • Honeywell Design Soultions (2002).

  • JCI Plastics Training Manual.

  • Injection Moulding Design by Pye


THANK YOU


Product Design & Development Steps

  • Design For Stiffness

    • Relation between load and deflection of the part is Stiffness

    • Determined by material and geometry of the part

    • Material Stress Strain Curves ( Young's Modulus)

  • Design For Strength

    • Max Load that can be applied to a part without resulting into part failure

    • Determined by Tensile stress strain curves( Tensile Strength etc)

  • Design for Behavior overtime

    • Creep : Time dependent Increasing Strain under constant stress

    • Stress Relaxation: Reduction of stress under constant strain


Product Design & Development Steps

  • Design for Impact Performance

  • Ability of material to withstand impulsive loading

  • Factors: type of material, geometry, wall thickness, size of component,

  • operating temp, rate of loading etc

  • Design for appearance

    • Sink Marks, weld lines, air traps, voids, streaks, delamination, jetting, gate marks etc

  • Design for precision

  • Design for moldability

  • Design for Recyclability

  • Design for automation


Part Application Requirement


Material Selection Process


Material Selection Process


Design Based Material Selection


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Guidelines for Injection Molded Design


Plastic Processing


Plastic Processing


Plastic Processing-Injection Molding


Plastic Processing-Injection Molding


Plastic Processing-IMD


Plastic Processing-Injection Molding


Assembly Techniques for Plastic parts


Assembly Techniques –Snap Fits

Snap fit cantilever beam type

Snap fit cylindrical Type


Assembly Techniques –Snap Fits

Factors for calculating cantilever beam for Snap fit


Assembly Techniques –Snap Fits

Mold Design For Snap Fits


Assembly Techniques –Spin Welding


Assembly Techniques –Ultrasonic Welding


Assembly Techniques –Hot Plate Welding


Assembly Techniques –Adhesive Bonding


Assembly Techniques –Ultrasonic Insertion


Assembly Techniques –Screw and Bosses


Assembly Techniques for Plastic parts


Injection Mold


Injection Mold


Injection Mold- Slider and Stripper Plate


Injection Mold- Stripper Plate


Injection Mold- Stripper Plate


Injection Mold-Hot Runner System


Tooling considerations for product design.


1. Maintain a uniform wall section - 2.0mm is typical. 2. Utilize the appropriate radii where applicable: 3. Strive to use snap fit and thread forming screws whenever possible to eliminate hardware, maximize design for assembly (DFA), and achieve the lowest cost.4. Draft is mandatory. 1.5 degrees per side, plus 1 degree per 0.001 depth of texture.5. Eliminate side draws (slides) and undercuts (lifters) whenever possible. Use through wall openings.6. Use the general tolerance box - tight tolerances drive up part and tooling cost.7. Do not put datum on flexible walls or points in space.

Plastic Design Major Messages


Rib to Wall Ratio

Typical Rules for Rib Thickness

Conventional Thermoplastics - 0.7T some sink mark will come

- 0.4T for part which is visible. Structural Foam - 1.0T


Uniform Wall Sections

It is important to use uniform walls to minimize warp age and maximize manufacturability potential.

Injection Molding : 2 to 4mmStructural Foam : 5 mmNo thin areas less than 1.5mmNo thick areas - core for uniform sections.

Always try to core from the ejector side of part.


Draft Angles

Draft is needed to facilitate release of part from mold.

The draft to use, unless otherwise specified, is 1.5 degrees per side.

Indicate if draft is to be added or subtracted from nominal dimension.

Show draft on part whenever possible to avoid confusion as to direction.

The "No Draft Allowed" is not to be used. Even on critical areas allow 0.5 degrees.


Limits of Undercuts

Eliminate undercuts by alternative redesign.

A minimum of 5 degree shut-off is required for all areas around a through opening. A 7 degree angle is even better.

See "Bad" steel conditions for steel limitations


"Bad" Steel Conditions

Generally, "Bad" steel conditions can be avoided if all standing steel has a height to width ratio of 1:1 or better.


Slide Core

Molded Part

Undercut

Horn Pin

Slide


Slide Core


Slide Core


Slide Core

Pulled Undercut


Slide Core

Pulled Undercut


Slide Core


Slide Core


Slide Core


Slide Core


Slide Core


Slide Core    


Slide Core

Excessive travel


Slide Core


Slide Core

Cover tool

Molded part

Horn Pin

Locking Block

Undercut

Spring

Slide core


Slide Core


Slide Core


Slide Core


Slide Core


Slide Core


Slide Core


Slide Core


Slide Core

Locking Block

Core pin

Molded part

Horn Pin

Undercut

Spring

Slide core


Slide Core


Slide Core


Slide Core


Slide Core


Slide Core


Slide Core


Slide Core


Slide Core


Slide Core


Accelerated Lifter    

Lifter

Undercut

Angled pin


Accelerated Lifter


Accelerated Lifter


Accelerated Lifter


Accelerated Lifter


Accelerated Lifter


Accelerated Lifter


Accelerated Lifter

Crash condition


Hydraulic cylinder

Core pin

Undercut

Hydraulic Cylinder


Hydraulic cylinder


Hydraulic pin


Ejecting molded part


Ejecting molded part


Actuating Core pin


Ejection of undercut part

Undercut

Hydraulic Cylinder

Slide Core


Ejection of undercut part


Ejection of undercut part


Ejection of undercut part


Ejection of undercut part


Ejection of undercut part


Ejection of undercut part


Ejection of undercut part


Ejection of undercut part  


Ejection of undercut part


Pendulum Core Pin


Pendulum Core Pin


Pendulum Core Pin


Pendulum Core Pin


Pendulum Core Pin


Pendulum Core Pin


Pendulum Core Pin


Pendulum Core Pin


Pendulum Core Pin


Pendulum Core Pin


Center Rib with Undercut

Undercut


Center Rib with Undercut


Center Rib with Undercut


Center Rib with Undercut


Center Rib with Undercut


Center Rib with Undercut


Center Rib with Undercut


Forced Ejection


Forced Ejection


Forced Ejection


Forced Ejection


Forced Ejection


Multiple Undercut

Molded Part

Slide

Hydraulic Cylinder


Die Opening


Die Opening


Lifter Ejection


Part Ejection


Lifter Return


Slide Return


Die Closing


Multiple External Slides

Locking Block

Core Pin

Molded part

Horn Pin

Undercut

Spring

Slide


Multiple External Slides


Multiple External Slides


Multiple External Slides


Multiple External Slides


Multiple External Slides


Multiple External Slides


Multiple External Slides


Multiple External Slides


Multiple External Slides


Multiple Undercuts


Multiple External Slides

Locking block

Core pin

Molded part

Horn Pin

Under

Spring

Slide


Multiple External Slides


Multiple External Slides


Multiple External Slides


Multiple External Slides


Multiple External Slides


Multiple External Slides


Multiple External Slides


Multiple External Slides


Multiple External Slides


Angled Lifter        

Molded part

Lifter

Undercut

Horn pin

Lose core


Angled Lifter


Ejection


Ejection


Ejection


Ejection


Die closing


Die closing


Die closing       


A

B

Impossible lifter condition

B

A


Thanks


Injection Mold-Hot Runner System


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