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This two day, total 16 hours, seminar is intended for all
personnel involved in product design and development; mold design; and quality assurance
of injection-molded parts and products. Components to be made out of synthetic materials
are not necessary injection-moldable items. Find out through participating in this
seminar, how to scrutinize product designs and recommend modifications so it will become
an injection-moldable part. This course provides an excellent introduction to the basic
polymer rheology and its relation to product design and process technology. Part design
criteria, correlation of polymer structure with product performance will be delivered in a
concise and practical manner.
At this seminar you will.... Understand the basis of
rheology and what this means to product design and development
Learn points to be considered when analyzing part function versus
screening candidate materials.
Broaden your understanding of the relationship between product
design, mold design, mold making and the molding operation.
Discover design techniques which will aid the ease of assembly.
Hear how to avoid typical plastic product design flaws.
Receive a comprehensive
custom-developed instruction manual, provided only to participants of this seminar, which
will serve as a valuable source in the future.
Seminar Outline
I Introduction to Polymer
Chemistry
- Definition of plastics, petrochemical source, classification
of plastics.
- Thermoplastic and thermosetting materials.
- Elements, atomic weight and energy bonds, monomers,
polymerization, macromolecules.
- Linear polymers with carbon and other atoms in the backbone.
- Molecular weight distribution.
- Polymer flow and variables in molecular orientation.
- Homopolymers, copolymers and terpolymers.
- Elastomers, alloys, additives, reinforcements and fillers.
- Crystal structure and spherulites growth during the mold
cooling process and its influence on product's rigidity, toughness, elongation and
dimensional behavior.
- Gating and cooling influence or effect on the part's
geometry.
- Understanding the hygroscopic polymers.
II Principle properties
of plastic
- Tensile strength, elongation, impact strength (Izod, charpy,
fallingdart), tensile impact.
- Designing for impact resistance.
- Measuring shrinkage from mold dimensions of molded plastics.
Deviations from assumed shrinkage: environmental dimensional change. Processing conditions
and post-molding shrinkage. Mold and manufacturing tolerances.
- Tolerances standards and practices of plastic custom
molders.
- Deflection temperature, compressive properties, flexural
properties, melt index, flammability.
III Plastics Additives Additives: Antimicrobials, Antioxidants, Blowing
Agents, Colorants, etc.
Fibers: Aramids, Carbon fibers, Glass fibers.
Fillers: Glass fillers, Mineral fillers.
Lubricants: Graphite powder, PTFE, Silicone fluids.
IV The Injection Mold
and Molding machine The injection molding machine: injection unit, clamp
mechanism, and machine specifications.
The injection mold: Type of molds with some examples.
The effect of machine setup parameters versus product
quality.
V
Plastic Product Design Evaluation
- Designing for uniform wall thickness and wall thickness
transitions; corner designs; rib designs; gussets; strengthening members; holes and
counter bores.
- Designing with parting line considerations and draft angles
in mind.
- Coring techniques and design locations for part ejection
(ejector pin, blade and sleeve marks).
- Designing for screw, rivets and fasteners assembly
techniques.
- Undercuts, threads and twist lock devices.
- Design techniques whereby the mold uses "by-pass
shut-off" instead of cam and sliding actions.
- Aesthetics: surface finishes, flow and weld lines, sink
marks, voids, and airtraps.
VI Snap joint techniques
- Flexible design techniques: Distortion snaps, press-fit
assembly, snap-fits, snap-hook designs, cantilever snap-joints, annular snap-joints,
latches, permanent snap design and twist snaps.
- Living hinges and hinge designs.
VII Other joining
techniques
- Ultrasonic welding, vibrational welding, spin welding, hot
plate welding, staking an swaging.
VIII Design - General
- Essential information to be agreed upon by product designer
and mold designer.
- Test your knowledge of plastic part design.
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