Interactive Online Training
Delivered online, Paulson Training Programs offers a thorough course on Part Design authored by industry expert, Kruse Training.
Goals of this Course:
- Learn the basics of part design and how various design elements impact a molded part
- Learn how to optimize different design elements to achieve high quality molded parts
Description of this Course:
As plastic part assemblies become more sophisticated, individual part design becomes more complex. This complexity can create challenges for part designers, as well as for mold designers and process engineers. At the beginning of a part design phase it Is important to establish design boundaries, allowing quality parts to be molded that meet specifications and expectations.
Explanations, simulations, cause and effect analyses, and the uses of these design features are considered since they will influence the moldability, function, appearance, and quality of a part.
Future Part Design Lessons will focus on rib spacing, corners, filets, radii, chamfers, flanges, rim design, blind holes and through holes, general rules for draft angles, and undercut designs.
Recommended For: Entry Level Personnel, All Personnel
Length: 9 Lessons (lessons are approximately 15-20 minutes long each)
Lesson 1, Part 1 – Nominal Wall Thickness
The first part of this lesson covers the importance of designing parts with nominal wall thickness, what factors play a role in determining nominal wall thickness, and how different materials and molding machine requirements impact nominal wall thickness.
Lesson 1, Part 2 – Nominal Wall Thickness
The second part of this lesson shows how to optimize gate and runner layout design when nominal wall thickness is already set, and how to evaluate injection pressure requirements to determine optimal gate and runner set-ups.
Lesson 2 – Flow Leaders
This lesson covers when and why to include flow leaders into a design, the potential process defects that can result from incorrectly designed and implemented flow leaders, and why flow leaders are instrumental in achieving uniform fill patterns in non-uniform designs.
Lesson 3 – Flow Restrictors
Flow restrictors redirect and restrain material flow and allow for uniform filling patterns. This lesson covers issues such as air entrapment, flow hesitations, and race-track effects when using flow restrictors in part design.
Lesson 4 – Rib Thickness
This lesson introduces ribs into part design and covers the factors to consider when using them, the importance of nominal wall thickness in determining rib thickness, and the effects of rib thickness on pack pressures, shrinkages, and sink marks.
Lesson 5 – Rib Height
This lesson covers how to determine optimal rib height based on nominal wall thickness and rib thickness, potential molding challenges of tall ribs, how different materials impact fill patterns for different rib heights, and how rib height impacts injection pressures, flow-front temperatures, and the frozen layer.
Lesson 6 – Rib Structure
Topics covered in this lesson include: the importance of fiber orientation in rib layouts to minimize warpage, the impact of different rib layouts on fill patterns, fiber orientation, and part warpage, whether thicker ribs will increase the stiffness of finished part, and why the number of ribs is not the primary factor in a part’s structural strength.
Lesson 7 – Corrugations and V-Grooves
This lesson covers the advantages and disadvantages of using corrugation and v-grooves in a part design, what other factors to consider when using these design elements, the effects of different layouts on fill patterns, and how different corrugation and v-groove layouts impact part flatness.
Lesson 8 – Bosses
This lesson covers how to evaluate various boss designs to determine the optimal design strategy, what risks are involved with incorporating boss designs into molded parts, and how to evaluate different boss designs in relation to filling behaviors, cooling temperatures, volumetric shrinkages, and sink marks.
Lesson 9 – Gussets
Learn how to evaluate the design, placement, size, and number of gussets in this lesson. Also covered are the impact of gussets on filling and cooling behavior, and how gussets affect volumetric shrinkages and flange warpage.