{"id":5655,"date":"2018-07-02T15:35:23","date_gmt":"2018-07-02T14:35:23","guid":{"rendered":"http:\/\/www.solidapps.co.uk\/blog\/?p=5655"},"modified":"2018-07-02T15:35:23","modified_gmt":"2018-07-02T14:35:23","slug":"understanding-plastic-part-design","status":"publish","type":"post","link":"https:\/\/www.solidapps.co.uk\/blog\/2018\/07\/understanding-plastic-part-design\/","title":{"rendered":"Understanding Plastic Part Design"},"content":{"rendered":"<p>Plastic parts are now commonplace in consumer product design, and for good reason. Highly durable, endless color options and of course, an inexpensive option when manufactured in high volumes.\u00a0 For the engineering and design team at URB-E, it was a no brainier to utilize plastic components for the fenders and battery hub in order to ramp up its production.\u00a0 But does this mean you have to be an\u00a0expert in plastics parts to be able to design one in SOLIDWORKS? Before we answer that questions, let\u2019s take a closer look at some critical design factors that govern a healthy\u00a0plastic part design.<\/p>\n<p>1) <strong>Drafted walls<\/strong><\/p>\n<ul>\n<li>The need to have drafted walls on injection molded plastics parts are simply an unavoidable\u00a0design feature. Having the right draft angles would ensure the part easily slides out of the mold\u00a0when ejected and avoid any costly damage to the plastic part and mold.\u00a0Using SOLIDWORKS, you can easily identify faces in your 3D model that require draft angles\u00a0using the draft analysis tool. This was an important step in the part seen below, which is the\u00a0battery case cover for the URB-E. This part was initially designed for form and function and 3D\u00a0printed, meaning drafted walls were not considered in the initially design stages.<\/li>\n<\/ul>\n<p><img decoding=\"async\" class=\"colorbox-38087\" src=\"http:\/\/blogs.solidworks.com\/solidworksblog\/wp-content\/uploads\/sites\/2\/2018\/06\/sasi_image201.png\" \/><\/p>\n<ul>\n<li>To use the Draft analysis tool, simply select a face that is parallel to the pull direction (direction out the part slides of the mold) and specify the minimum allowable draft angle. The 3D model will then be colorized to show faces with positive, negative or no drafts.<\/li>\n<\/ul>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"colorbox-38087\" src=\"http:\/\/blogs.solidworks.com\/solidworksblog\/wp-content\/uploads\/sites\/2\/2018\/06\/sasi_image202.png\" width=\"650\" height=\"420\" \/><\/p>\n<ul>\n<li><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">In addition to ensuring the part ejects without any issues, the positive or negative color codes will help<span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span>determine where parting line and or shutoffs could be located.<span class=\"goog-inline-block\">\u00a0<\/span><\/li>\n<\/ul>\n<p><span class=\"goog-inline-block\">2) <strong>Avoiding Undercuts<\/strong><\/span><\/p>\n<ul>\n<li>U<span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">ndercuts in the plastic part design could cause the part to be stuck within the mold after it has formed.\u00a0\u00a0<\/span><\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">This typically results in a lot of redesign time and mold reworks, which can be very time-<\/span><\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">consuming and not to mention costly as well. Undercuts should be avoided at all cost. Similar to<span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">the draft analysis tool, the Undercut Analysis is located in the Evaluate tab.<span class=\"goog-inline-block\">\u00a0<\/span><span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><\/li>\n<\/ul>\n<p><img decoding=\"async\" class=\"colorbox-38087\" src=\"http:\/\/blogs.solidworks.com\/solidworksblog\/wp-content\/uploads\/sites\/2\/2018\/06\/sasi_image203.png\" \/><\/p>\n<ul>\n<li><span class=\"kix-wordhtmlgenerator-word-node\"><span class=\"goog-inline-block\">\u00a0<\/span><\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">The undercut analysis tool allows the user to specify either the pull direction (like the Draft analysis tool)<span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">or the actual parting line to identify features that may cause undercuts.<span class=\"goog-inline-block\">\u00a0<\/span><span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><\/li>\n<\/ul>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"colorbox-38087\" src=\"http:\/\/blogs.solidworks.com\/solidworksblog\/wp-content\/uploads\/sites\/2\/2018\/06\/sasi_image204.png\" width=\"650\" height=\"446\" \/><\/p>\n<ul>\n<li>Looking at this image above, we seem to be in good shape for this URB-E battery case cover.<span class=\"goog-inline-block\">\u00a0<\/span><span class=\"goog-inline-block\">\u00a0<\/span><\/li>\n<\/ul>\n<p><span class=\"goog-inline-block kix-lineview-text-block\">3)\u00a0\u00a0<\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\"><strong>Will the part fill during injection molding?<\/strong><span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span> <span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\"><span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><\/p>\n<ul>\n<li>SOLIDWORKS modeling tools such as shelling, ribbing and surfacing help a designer model plastics parts<span class=\"goog-inline-block\">\u00a0<\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">quickly and easily. However, the age old question is: will the plastics part fill completely within the<span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span>mold? Wall thickness, injection location, material viscosity and injection pressure are few<span class=\"goog-inline-block\">\u00a0<\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">parameters that can determine if the part forms completely or experience a short shot.<span class=\"goog-inline-block\">\u00a0\u00a0<\/span><\/span><\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">SOLIDWORKS Plastics uses intuitive, easy-to-use tools to quickly determine how the mold will fill.<span class=\"goog-inline-block\">\u00a0 I<\/span><\/span><\/span>f gives uses an inside look into how the liquefied plastic flows and forms within the mold cavity.<span class=\"goog-inline-block\">\u00a0<\/span><span class=\"goog-inline-block\">\u00a0<\/span><\/li>\n<\/ul>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"colorbox-38087\" src=\"http:\/\/blogs.solidworks.com\/solidworksblog\/wp-content\/uploads\/sites\/2\/2018\/06\/sasi_image205.png\" width=\"650\" height=\"540\" \/><\/p>\n<ul>\n<li>In addition to viewing the flow, SOLIDWORKS Plastics will help a designer determine if any features are<span class=\"goog-inline-block\">\u00a0<\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">causing a difficulty in filling or if spikes in injection pressure would in turn cause gate freezing<span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span>issues. Being able to identify these flow problems early will help the re-design process of the<span class=\"goog-inline-block\">\u00a0<\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">part without having to guess the most optimized design.<span class=\"goog-inline-block\">\u00a0<\/span><span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><\/li>\n<\/ul>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"colorbox-38087\" src=\"http:\/\/blogs.solidworks.com\/solidworksblog\/wp-content\/uploads\/sites\/2\/2018\/06\/sasi_image206.png\" width=\"650\" height=\"543\" \/>\u00a0<span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\"><span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><\/p>\n<ul>\n<li>To take this a step further, SOLIDWORKS Plastics also identifies weld lines within the model at the end of<span class=\"goog-inline-block\">\u00a0<\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">the filling stage. For example, with this battery case, weld lines in critical areas could cause the<span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">part to break during operation if it endured a high-force impact on it, such as the URB-E riding over<span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">a pothole. Weld lines can typically move to non-critical areas by modifying the geometry or<span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">changing the gate location. Both can be done quickly within SOLIDWORKS Plastics to see how the<span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">changes would effect the filling process.<span class=\"goog-inline-block\">\u00a0<\/span><span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><\/li>\n<\/ul>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"colorbox-38087\" src=\"http:\/\/blogs.solidworks.com\/solidworksblog\/wp-content\/uploads\/sites\/2\/2018\/06\/sasi_image207.png\" width=\"650\" height=\"547\" \/>\u00a0<span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\"><span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><\/p>\n<p><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">So, what is the answer to question that opened this article? Using the tools that are fully integrated<span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">within SOLIDWORKS, there is little to no reason why a less experienced plastic part designer wouldn\u2019t be<span class=\"goog-inline-block\">\u00a0<\/span><\/span><\/span><span class=\"goog-inline-block kix-lineview-text-block\"><span class=\"kix-wordhtmlgenerator-word-node\">able to design a functional plastic part.<\/span><\/span><\/p>\n<p>&nbsp;<\/p>\n<p>Originally posted in the <a href=\"http:\/\/blogs.solidworks.com\/solidworksblog\/2018\/07\/understanding-plastic-part-design.html\" target=\"_blank\" rel=\"noopener\">SOLIDWORKS Blog<\/a>.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Plastic parts are now commonplace in consumer product design, and for good reason. Highly durable, endless color options and of course, an inexpensive option when manufactured in high volumes.\u00a0 For&hellip; <\/p>\n","protected":false},"author":1,"featured_media":5656,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[5,73],"tags":[25,119],"class_list":["post-5655","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-solidworks","category-solidworks-plastics","tag-solidworks-2","tag-solidworks-plastics"],"post_mailing_queue_ids":[],"_links":{"self":[{"href":"https:\/\/www.solidapps.co.uk\/blog\/wp-json\/wp\/v2\/posts\/5655","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.solidapps.co.uk\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.solidapps.co.uk\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.solidapps.co.uk\/blog\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.solidapps.co.uk\/blog\/wp-json\/wp\/v2\/comments?post=5655"}],"version-history":[{"count":2,"href":"https:\/\/www.solidapps.co.uk\/blog\/wp-json\/wp\/v2\/posts\/5655\/revisions"}],"predecessor-version":[{"id":5658,"href":"https:\/\/www.solidapps.co.uk\/blog\/wp-json\/wp\/v2\/posts\/5655\/revisions\/5658"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.solidapps.co.uk\/blog\/wp-json\/wp\/v2\/media\/5656"}],"wp:attachment":[{"href":"https:\/\/www.solidapps.co.uk\/blog\/wp-json\/wp\/v2\/media?parent=5655"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.solidapps.co.uk\/blog\/wp-json\/wp\/v2\/categories?post=5655"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.solidapps.co.uk\/blog\/wp-json\/wp\/v2\/tags?post=5655"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}