플라스틱 디자인 팁 모음

플라스틱 설계 이론은 없고, 사출 성형으로 구현 가능한 가장 일반적인 플라스틱 설계 특징들을 풍부한 그림 예시로 보여줍니다. 사출 성형에 최적화된 플라스틱 설계가 어떻게 현실화되고, 가장 저렴한 대량 생산 기술이 되는지 보여줍니다.

이 컬렉션은 시간이 지남에 따라 확장될 예정입니다.
-아이디어, 의견 및 사진을 제안해 주세요-

플라스틱 클립 디자인

플라스틱 사출 성형이 탁월한 성능을 발휘하며 다른 기술로 대체하기 어려운 점은 다음과 같습니다. 뛰어난 유연성, 커버에 추가되는 공간이 적음, 단 두 부분으로 구성된 간단한 금형 설계만으로 구현 가능, 끝단 정지용 리브, 사용자 표시 등 다양한 기능 제공.

플라스틱 보강 설계

일반적으로 금속 부품을 추가하여,

• 실제로 최종 조립 단계에서 부품 하나를 추가하는 것만으로도 가능합니다 (예: 조립 시 육각형 홈에 간단한 너트를 넣는 것).
• 오버몰딩 방식으로 제작되며, 일반적으로 금속 부품에 적용됩니다 (금형에서 유지하는 데 사용되는 치수, 즉 적어도 한 치수에 대해 엄격한 공차가 필요합니다).
• 금속과 플라스틱을 조립할 때, 꽉 맞물리거나 스프링 효과를 이용합니다.

Plastic Latch Design

Made in two parts.

Nice cinematic to be operated by hand but would not detach with pull force once closed. Typically clearances on-axis & material flexibility are necessary for such applications.

An additional no-cost plastic-included function is the ability to block it with a screw, or in other cases with a lock.

Note the protrusion variant on the transparent cover to have one version that can not be dismounted on either side (in this case to retain the plastic cover from the lamp, when hanging on the ceiling)

Fragile Wall to be punched by user

Permits some flexibility in sizes of counterpart or common parts to be used in different variants or designs … at the cost of not visually perfect edges. Note the reinforcement rib around the surface to be punched and the channels to feed the inner surface.

This wall is not particularly easy to remove: the wall thickness could have been thinner than that and easier to punch, but the recess would likely have been more visible on the other side.

Plastic Ribs Design

The typical plastics classic feature is hardly obtainable by any other technology than injection (or Mazac, aluminum…). Its thickness should ideally be a third of the main wall thickness to avoid recess on the other side.

팁: mind that thinner ribs will limit or suppress the recess on the other side but may be problematic if you need a fire-resistant design (plastic materials are frequently guaranteed fire-resistant only if a minimum thickness is respected)

Plastic Living Hinges Design

One of the smartest design features possible with plastic, but also the one requiring the best cooperation with the mold + process team, as the exact design depends more than any other on the material choice and mold design options.

As long as the product is not too big, it permits avoiding additional parts & molds, so as assembly operations.

Initially used for low-cost packaging (food, sauce, liquids …) to connect the lid to the main box, it can also be used for product housing as long as the hinge is somehow hidden or on a back surface (example in the gallery below)

Points of interest for product design

• injection point/gate location is critical, as some material will have to flow perpendicular across the thin hinge section. In case of several gates, mind not to join the flows at the hinge
• If several hinges are required, the injection point/gate will typically be placed in the center of the two, to avoid the flow to cross both hinges one after the other (which would decrease pressure & injection speed)
• hinge thickness typically from 0.2 to 0.4mm, with connecting radius & chamfers
• in some cases, manipulating the hinge just after injection is required (can be part of the ejection system)
• for long-lasting products, the design should incorporate some angle limiters pins, or stoppers to control the start & end positions 
• the material of choice is PP
• some new prototyping materials permit to obtain living hinges as in production processes

typically made out of plastic injection, it can also be made in other materials (leather, wood …) so as obtained with post-processing (milling, stamping…)

… although some of these techniques will impact the durability of the hinge

Plastic Parting Lines Design

Parting lines are not exactly a feature but a consequence of mold designs being in two -or more- parts and other recess or kiss-off surfaces.

Being wise in that area is where one makes mold cost savings. On the other hand, parting lines are usually where you first see the quality of the mold (enough thickness & rigidity, quality of the steel) and the wearing and maintenance over time.

Plastic Locating Pins Design

In any kind of shape, form & size, either to locate bottom+top plastic parts together or to fix some components

Plastic Overmolding – Bi-materials

Either mix different properties (ex: soft+hard) or have different colors or replace metal (lighter or cheaper objective).

Because of the additional mold required, or an advanced mold with several cavities or sides, plus the placing robot placing the first part into the mold (usually), this technique is mostly for high runner parts.

Plastic Cable Guides & Cable Fixtures Design

Mostly used in home appliances, with or without screws depending on the required pull force to withstand.

To Dive Deeper into Plastics

• Injection molding techniques: advanced methods for optimizing the injection molding process to improve efficiency and reduce defects.
• Material selection criteria: guidelines for selecting appropriate plastic materials based on mechanical properties, thermal resistance, and environmental impact
• 유한 요소 Analysis (FEA): simulation techniques to predict how plastic components will behave under various stresses and conditions
• 적층 제조 (3D Printing): techniques for using 3D printing to create plastic prototypes and end-use parts, including material considerations
• Surface treatment methods: processes such as 코팅, painting, or texturing to enhance the appearance and functionality of plastic surfaces
• Thermoforming processes: techniques for shaping plastic sheets into specific forms using heat and pressure
• Blow molding Innovations: advanced methods in blow molding for creating hollow plastic parts with complex geometries
• Design for Manufacturability (DFM): principles that ensure plastic parts are designed in a way that simplifies manufacturing processes
• Sustainability in plastics: approaches to designing and engineering biodegradable or 재활용됨 plastics to reduce environmental impact
• Composite materials engineering: techniques for combining plastics with other materials (e.g., fibers) to enhance strength and performance
• Quality control techniques: methods for ensuring consistency and reliability in plastic products through statistical process control and testing
• Thermal management in plastics: strategies for managing heat dissipation and thermal stability in plastic components
• Joining technologies for plastics: techniques such as ultrasonic welding, adhesive bonding, and mechanical fastening for assembling plastic parts
• Coloring and additive masterbatch techniques: methods for incorporating color and functional additives into plastics during processing

사용된 용어집

Design for Manufacturability (DFM): 제조 공정을 단순화하고 최적화하여 생산 비용을 절감하고 품질을 향상시키며 제품 출시 기간을 최소화하기 위해 설계 단계에서 제조 능력과 제약 조건을 고려하는 것을 목표로 하는 일련의 엔지니어링 관행입니다.

Finite Element Analysis (FEA): 복잡한 공학 문제를 해결하기 위한 수치적 방법으로, 구조물을 요소라고 하는 더 작고 단순한 부분으로 분해하여 다양한 조건에서 응력, 변형률 및 변형을 분석할 수 있게 합니다.

Metal Active Gas (welding) (MAG): 철금속과 비철금속을 접합하는 과정에서 소모성 전극을 지속적으로 공급하고, 일반적으로 이산화탄소를 포함하는 보호 가스 혼합물을 사용하여 용접 풀을 대기 오염으로부터 보호하는 용접 공정입니다.

Metal Inert Gas (welding) (MIG): 용접 건을 통해 공급되는 연속적인 고체 와이어 전극을 사용하여 와이어와 공작물 사이에 전기 아크를 발생시켜 둘을 녹여 용접 풀을 형성하는 용접 공정입니다. 일반적으로 오염을 방지하기 위해 불활성 가스로 보호됩니다.

Statistical Process Control (SPC): a method of quality control that employs statistical techniques to monitor and control a process, ensuring it operates at its full potential by identifying variations and maintaining consistent output within specified limits.