The Importance Of Plastic Product Design
Plastic products occupy a very important position in the entire manufacturing industry, their molds account for almost 40% of the entire mold industry, and their advantages are also very obvious. However, the design of plastic products has their own unique requirements and rules. It must be completed by professional designer. Based on decades of experience in the plastic molding industry, FMS design team will benefit your products
Advantages Of FMS Plastic Product Design
FMS product designers have unique advantages in the design of plastic products, at first, Our experience in injection molding simulation analysis and injection mold design benefits our plastic product design. secondly, We are located in the most concentrated area of injection mold making and injection molding production in the world. it allows us to access all kinds of mold makers and injection molding companies, and expose us to new designs and molding techniques. these also benefit our plastic product designers, Our service is professional, efficient, integrity, good quality but not expensive
The Style Of Plastic Product
Injection molded plastic products can be designed to provide good looking products that consumers want to buy at no additional cost over boring products that have no sales appeal. To do this, you need the right product concept, the right people, and the right tools. Almost all of the new products on the market today are designed using industrial strength solid modeling CAD systems with good surface modeling capabilities such as UGNX. Our experience in UGNX surface modeling gives us the skills and tools we need to create competitively priced parts designed for economical injection molding
Just the right tools are not enough to create good looking parts. A designer with a sense of style who is working with an strong look concept is required to deliver a product look that will sell. Our experience in creating attractive plastic parts in UGNX can help you turn the idea of a good product into the physical reality of a well-designed plastic product.
Productive Design
Parts made of plastic must be “designed for production” than any other material. Almost everyone can design a plastic product to a certain extent, but in order to do it well, in addition to the “conventional” design skills, you need to understand the injection molding process and the function of the injection mold. We have previously provided our customers with the services of our injection mold design, and we have a deeper understanding of injection molds and injection molding issues. This knowledge, combined with our UGNX and FEA stress analysis capabilities, provides us with a powerful background in the design of plastic products
The importance of plastic stress analysis
The structural characteristics of plastic are very different from those metals, which is no longer news. But even a common term like stress, the meaning of a plastic part is very different from the meaning of a metal part. The real question is how do these different material properties affect the design process?
Plastics are considered to be a low cost material, but in reality they are quite expensive from a unit volume or load bearing point of view. Due to the high speed of the injection molding process, the cost of plastic parts is low. With this in mind, 100% of plastic products are not always the best way to get the most cost-effective products.
Plastics are generally good at handling intermittent loads, but they are permanently deformed even at low long-term loads. Often, a reasonable amount of plastic can not be added to overcome this characteristic in the design, so adding a small amount of load bearing metal parts to the main plastic design will result in a better product.
Designing a plastic part for manufacturability involves many important factors that touch on all areas of part design, tooling, material selection and production. First, it is essential to build parts around functional needs by keeping design intent or the end use in mind. Consider weight reductions, the elimination of fabrication and assembly steps, improving structural components, reducing costs and getting products to market quicker.
Now, if this is your first approach to plastic product design, you’re probably thinking about what the primary factors are to look for this service resource. To make the most appropriate decision making to your business needs, here are some useful considerations to think about and share with your designer/supplier combo:
Why is this design necessary?
Which need are we trying to meet?
How will its function help our product?
Are we going to replace other existing products?
Are there already similar products on the market?
Are there any patents or protected designs that could conflict with this new design?
How will its use and usability criteria make our product attractive to the final consumer?
Who is its potential user?
Are there any possibilities of misuse of my product that could harm the user?
Will it be a single-use product? How many uses will it have?
Is it a seasonal product?
Is it a promotional product?
How important is the appearance of the product?
Plastic design is a combination of geometry and choice of materials. These two factors interrelate with each other, and knowledge of each area is important to achieve a comprehensive design. For plastic design, there are specific rules regarding part geometry, which supports in achieving the intended embodiment.
To manufacture a new plastic product design, your supplier must have knowledge of industrial design, materials, industrialization, and product management, once its life cycle is over. Elements such as walls, ribs and holes require detailed scrutiny, for which general design guidelines and checklists provide basic principles.
if you’re new to designing molded plastics or if you’re curious about the process.
Use a uniform wall thickness. This will promote uniform patterns, uniform molded-in stress distribution and uniform shrinkage. Having a uniform mold will also make warping less likely.
Avoid abrupt transitions from thin to thick. All parts require some variations with wall thickness including features such as ribs. Because of the structural differences, the transition should be as gradual as possible in order to avoid flow hesitation.
Avoid sharp corners as much as possible. Sharp corners act as stress concentrators that can lead to crazing, cracking, increased susceptibility to chemical attack and part failure. To best avoid sharp corners with plastic product design, use generous radius at all corners. Radius corners make it really easy to add fillets or chamfers to avoid sharp corners altogether.
Use ribs to improve part stiffness in bending. Ribs are also used in plastic parts to prevent warpage. If ribs aren’t designed properly relative to the surfaces they’re attached to, problems such as sink marks, warpage and part failure can occur.
Use the least thickness compliant with the process, material or product design requirements. This will ensure rapid cooling, short cycle times and minimum shot weight. Combined, this will result in the least possible part cost.
Try to design parts to facilitate easy withdrawal from the mold by adding draft in the direction of mold openings or closings. The amount of draft angle depends on the depth of the part in the mold and its required end function.
Designing a plastic part for manufacturability involves many important factors that touch on all areas of part design, tooling, material selection and production. First, it is essential to build parts around functional needs by keeping design intent or the end use in mind. Consider weight reductions, the elimination of fabrication and assembly steps, improving structural components, reducing costs and getting products to market quicker.
Injection molding is not the one and only perfect plastic manufacturing method. However, it has its set of disadvantages but the benefits clearly outweighs its cons with a huge disparity. All of these information on how to design plastic products through injection molding may seem so sketchy if you are still new to plastic manufacturing. It needs time and experience before you get yourself fully acquainted to injection molding as a method on how to design plastic products. An experienced plastics manufacturing company can help you with the details.
Getting great results from plastic injection molding requires a respect for the properties of thermoforming plastic resins and how they behave inside of a mold tool. Using good design practices at the beginning of the product development cycle will help you to avoid common pitfalls and will improve the look and performance of your parts. you always are some suggestions for the most common causes of defects in plastic injected molded parts and how to avoid them for our next project. thanks you so much!
Designing uniform wall thickness is essential to controlling the distribution of heat within the part during molding.
To get the best results, follow these design tips for wall thickness. Be careful to note the type of plastic being molded, which may effect the rate of shrinkage in the mold.
Adjacent walls should be equal in thickness wherever possible, but should in no case differ more than ~50%
Long wall sections should be supported with ribs or gussets, instead of making them thicker for strength
There should be a draft angle of 1 degree for every 2 cm in wall height
Walls should have a slight radius at their base to relieve stress which can cause cracking or deformation
Material and Thickness are very important when designing a plastic product
Depending on (1) how the product works, (2) the environment it will be in and (3) the preference of the designer, a material should be selected. These materials change how the part feels, looks and operates. Some are flexible, some are rigid, some are strong, some are brittle. The type of material chosen will often have a significant effect on the design of the part. Some support ribs may need to be removed or added, walls may need to be thicker or thinner, etc.
The plastic product design process offers many versatile solutions and unique benefits, but it’s a practice that depends on the strength of its design. The injection molding part design must be developed to maximize the efficiency inherent in high-volume molding. Plastic product and mould design, tool building, plastic material selection, and Injection molding manufacturing process are the four key factors that go into making a high-quality plastic injection molded part. During both the injection and cooling stages of the manufacturing process.
There are some differences between plastic product design and other product design. Here I would like to share some experience about plastic product design:
1. Wall thickness
Thin walls are advisable in plastic manufacturing for shorter cycle times and being able to produce more plastic part designs in shorter production lead time. Thinner walls also makes the cooling process faster. Ideal wall thickness from 0.08″ (2mm) to 0.16″ (4mm), but thin wall injection molding can go as thin as 0.02″ (0.5mm).
However, wall thickness also depends on the type of plastic material being used. Here are the recommended wall thickness for various plastic materials; ABS resin is between 0.045 and 0.140 inches, Acrylic is at 0.025 –0.150, Liquid crystal polymer at 0.030 -0.120, Nylon at 0.030–0.115, Polycarbonate at 0.040 – 0.150, Polyester at 0.025 –0.125 and Polypropylene at 0.025– 0.150.
2. Ribs
Adding ribs helps increase the bending stiffness due to the increased moment of inertia. This is a suggested option instead of adding thickness to the wall. Here are recommendations with ribs in plastic production;
Rib’s thickness should not be more than 60% of the nominal thickness value.
Height should be three times lower than the wall thickness.
Draft angle is at 25 degrees.
The ribs position must be perpendicular to the axis where the bending occurs.
Corners of the attachment points must be rounded instead of having them pointed.
3. Bosses
Bosses are layers wherein fasteners are attached and threaded inserts are located. Recommended specifications for bosses are the following;
Bosses’ wall thickness should not be more than 60% of the main wall.
Base radius should be at least 25% thickness of the main wall.
Bosses should be supported by ribs connecting to walls adjacent from their position or gussets at the bottom the mold design.
Ribs should be used to isolate bosses in corners of the design.
Plastic product designer’s Services include dynamic, linear and non-linear analyses, consulting, CAD development and design and prototyping.
Plastic Part design could become tricky and compromises and trade-offs usually lead to failures. Automotive OEM’s will mainly use plastic material in cosmetic components and some other non-load carrying components.
Main features of plastic part design would include:
Good Knowledge of Material Database – There are many sources of data available for 100’s of plastic material types and grades in the market. But very few would provide complete understanding of material properties. When select the plastic materials, temperature and time variation of strength should be considered, as it could significantly lead to development of creep & fatigue.
Type of Loading & Application – Short term cyclic loading or long term constant load. In both cases, the maximum allowable stresses are going to be significantly lesser than the tensile strength of material. The environmental exposure of the part can also decide the life of the part as it degrades on coming in contact with chemicals, UV rays, sunlight and temperature.
Part Design Features – Many factors like ribs, notches, wall thickness, holes can contribute to stress concentration & residual stresses in the part. Thus careful consideration of part features should be done in order to optimize the stress lines within the part. For example, any abrupt change in wall thickness may lead to high stress concentration and thus reduce strength of the part.
Process Induced issues – process control parameters like cooling time, heating temperature, poor material mixing, poor part design leading to improper material flow can significantly affect the structural characteristics & quality of the part.
Basically, the manufacturer try to cut costs by compromising on either of these factors which should be taken care by the product engineering team of the automotive company.
When designing with plastic, our goal is to achieve a technically accurate design that works well and can effectively reduce manufacturing costs. Following these basic techniques will help achieve these goals and speed up the design process.
Today’s high-performance plastics bring many benefits to the design table, which was previously thought to be only available on metal. The first is durability. Over time, today’s high performance plastics have proven to be much stronger than metals in many applications. Every imaginable industry, from plumbing, medical and aerospace, now has hundreds of applications, and previously designed metal parts are converted into plastic.
Uniform wall thickness is the key to the design of molded parts. Uneven wall thickness can cause dimensional integrity problems such as dimensional control problems and warpage.
Material Selection – Some materials can flow through thin-walled sections and provide the proper strength for their application. However, some materials are not free to move or contain fillers to increase the strength of the selected material. These types of materials require a thicker minimum thickness.
Mechanical properties required for part integrity – What are the design requirements for the part? If this part is under constant load, it may require a thicker wall section than without any load.
There are hundreds of plastic materials to choose from, all with different performance characteristics. You need to know which plastic is best for your application. You should also understand the pressures that affect product performance and longevity. The key question to answer is: Will some of the pressure be repeated or a one-time occurrence? Is the stress of the moving plastic part in continuous peak load and slack, or in a constant load state? What chemicals will come into contact with the part? Some plastic pairs Certain chemicals are very sensitive, while others are not. Both plastic material suppliers and experienced molds will prove helpful in selecting the right materials for the application.
Designing products with molded plastic parts and components is becoming a more attractive option. New high performance plastics and innovative molding processes make this possible. Injection molded plastic parts provide an important combination of flexibility, toughness, and chemical resistance for cost-effective, long-term performance in a range of applications. However, not every plastic part is designed to be injection molded efficiently. Therefore, working with experienced molders with years of experience in high-performance plastics and complex projects is critical to successful results. This way, you can be sure that your molded components and components are functional and within budget.
There is no doubt about the importance of industrial design to a country
I have been engaged in industrial design for five years. I think it is not easy to become a qualified industrial designer
As an industrial designer, I am very proud of my work，Because it changed many people’s lives
Industrial design has a wide range. I think we need a platform for communication. Maybe this is a good idea
I am an industrial designer, and I think we can exchange some experience about plastic product design when we are free
hi dean, we are glad to do so, you are welcome anytime!
In my opinion, your industrial services are limited to the design of plastic products. I mean Industrial design is a big concept
In my opinion, to become an excellent industrial designer, we need to learn a lot of knowledge and experience, and talent is also important
The overall level of industrial design also matches the economic development of this country
In my opinion, industrial design reflects the overall technical level of a country.
A good industrial designer needs to be passionate, innovative and socially responsible.
But I think the ultimate mission of industrial designers is to change our lives, even our world, but there are very few industrial designers like that.
If every industrial designer could be jobs, the world would be horrible.
But it is very difficult to be such an industrial designer.
I absolutely believe that a good industrial design can change your life.
In industrial design, product design and functional design can almost determine the success or failure of a product.
My major in college is industrial design, and I prefer hand-drawing class， because it is more free to express my ideas.
You’re right, I’m an industrial designer, but my job in our company is just to finish some new product’s appearance design
I admit that my understanding in industrial design is incomplete. After reading this article, I think I need to re-understand industrial design.
Industrial design involves a lot of knowledge and experience in many industries.
A complete industrial design usually requires a team to complete.
Creativity is a very important and necessary condition for a good industrial designer.
Now CAD is becoming more and more popular in industrial design, but I think hand-painting is still an important basic skill.
In modern industry, the role of industrial design will become more and more important.
In fact, I think apple’s most successful is their industrial design, which has a very good industrial design team.
Inspiration is very important for industrial designers. as an industrial designer, I can understand
There are few industrial designers who can change your life around the world.
Yes, a complete industrial design involves a lot of knowledge and industry. For example, the design of plastic products involves injection molding technology and mold manufacturing technology.
In my opinion, you are better at designing plastic products.Because you have a lot of experience in plastic molding.
I am an industrial designer and I think genius is very important as a qualified industrial designer.
Many people think that industrial design is just an Appearance design and structural design, which is very wrong.
In industrial design, the combination of different materials is the most problematic.For experienced industrial designers, they know how to deal with these problems
It is not so easy to design a perfect plastic product, at least you have to have injection molding and plastic mold knowledge.
A good industrial designer should have a strong comprehensive ability and a deep understanding of the trends in the industry.
Industrial design is a system engineering, and the plastic products you designed are only part of the industrial design.
Yes, the design of plastic products has its particularity. Your experience in plastic molding can help you design the plastic products.
Industrial design reflects the comprehensive strength of a country. Your company seems to be better at designing plastic products.
it seems that we can help you to do industrial design
I think at least in industrial design field, we can do something together, we focus on it
maybe that is a good idea! please feel free to contact us
I am glad to know you can provide that kind of service for your customers, you know, that will help them a lot.
A successful industrial design can change our lives
Industrial design concept is much larger than your description
A good industrial designer needs to learn a lot of knowledge
your understanding on industrial design is correct
it seems that your company has a professional industrial design team. that is a good news for your customers
I hope more and more industrial designer coming here to share and discuss something about industrial design.
I think you should cooperate with our company, because we are a professional industrial design company
industrial design is very important for every new product
your understanding in industrial design is correct
China is advocating innovation reform, It will promote the development of industrial design
Industrial design level embodies the comprehensive strength of a country
industrial design is very important for every country
I am an industrial designer, I think you understnad industrial design very well.
industrial design is a creative job
China needs a large number of outstanding industrial designers。
Industrial design is a complex technical activity
You understand industrial design perfectly
I am industrial designer, we could discuss some issues here in the future
you understood industrial design very well
your industrial design team is very good
you understand the essence of industrial design.But it is hard to find a good industrial designer
an excellent industrial design can change our life
Industrial design is a creative work, It needs momentary inspiration
industrial designer needs talent
Industrial design is not a simple imitation
The essence of industrial design lies in the innovation rather than copy
the product positioning is also very important, Because your product is impossible to be suitable for anyone
you understand the essence of industrial design
Industrial designer needs momentary inspiration when he or she is designing a product
We are an industrial design company, we are willing to share some experiences with you
thank you very much!
We are a professional industrial design company.We can learn from each other
I think your industrial design service only complete the part of the whole industrial design
I think we can discuss some experience about exterior design
an Excellent industrial design will change our life
industrial design is a very large concept
I think your industrial design service is limited to appearance design and structural design
I suggest you should try to do your own products, you do have enough ability
it is hard to design products that popular with consumers. Industrial designers need to master a lot of knowledge
I don’t think Chinese industrial design level is low
The level of industrial design in China is still very low，the innovative design is very few
We are an industrial design company in London, England.I have sent an email to you
South Korea’s industrial design level is also good
In my opinion, the level of industrial design in China has had a very big enhancement
Apple’s products are the model of industrial design
France’s industrial design level is higher than China’s.
The level of industrial design reflects the scientific and technological level of a country
I think you can provide one-stop service to your customers, but Industrial design is a difficult job
Australia’s industrial design level is good too
Compared to the past, the level of industrial design in China has had a very big enhancement
Britain’s industrial design is also very excellent
The industrial design level in United States, Japan, Germany, Italy, South Korea is much better than china’s
Hi we are a professional industrial design company, we are gald to know that you also provide industrial design services. I believe that cooperation is a good choice, what do you think? our Email address was sent to you, and we are looking forward to your response
I think an excellent industrial designer can help a lot of companies to make money
Industrial design is a hard work,It needs talent and inspiration.
At least in Germany, industrial design level is very high. Chinese is also very smart
Hi,you understand the essence of industrial design
Industrial design is an innovative work, I would like to learn from you
I’ve learn several excellent stuff here. Certainly worth
bookmarking for revisiting. Industrial design is a creative job,more communication would be better for your team
industrial design is a big design, your team must face the whole process, it seems that you can do it
we are an industrial company, I am glad to meet colleagues here. after reading this piece of article, I think we can try to do some projects together
I am glad to find you provide industrial design service, as an industrial designer, I think, maybe we could discuss something together, I will try.
I want to say industrial design is a big concept, I mean It includes the whole process of products, you know mold design and mold manufacturing and molding process are just part of it
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to read everthing in mold technologyat this website. as for industrial design, I want to share some experience, but…actually, that is a big problem, because Industrial design is a creative job.
I am glad to see you provide industrial design service, maybe we can discuss something about it here.
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