7 Product Design

- 1 [de]
  - 1.1 [de]
- 2 [de]
  - 2.1 [de]
  - 2.2 [de]
  - [de]
- 3 [de]
  - 3.1 [de]
  - [de]
- 4 [de]
  - 4.1 [de]
  - 4.2 [de]
  - 4.3 [de]
  - 4.4 [de]
    - 4.4.1 [de]
    - 4.4.2 [de]
    - 4.4.3 [de]
  - 4.5 [de]
    - 4.5.1 [de]
    - 4.5.2 [de]
    - 4.5.3 [de]
    - 4.5.4 [de]
  - 4.6 [de]
  - [de]
  - 4.7 [de]
    - 4.7.1 [de]
    - 4.7.2 [de]
      - 4.7.2.1 [de]
      - 4.7.2.2 [de]
    - 4.7.3 [de]
      - 4.7.3.1 [de]
      - 4.7.3.2 [de]
      - 4.7.3.3 [de]
      - 4.7.3.4 [de]
      - 4.7.3.5 [de]
    - 4.7.4 [de]
      - 4.7.4.1 [de]
      - 4.7.4.2 [de]
      - 4.7.4.3 [de]
      - 4.7.4.4 [de]
      - 4.7.4.5 [de]
    - 4.7.5 [de]
    - 4.7.6 [de]
    - 4.7.7 [de]
    - 4.7.8 [de]
  - [de]
  - 4.8 [de]
    - 4.8.1 [de]
    - 4.8.2 [de]
      - 4.8.2.1 [de]
      - 4.8.2.2 [de]
      - 4.8.2.3 [de]
      - 4.8.2.4 [de]
    - 4.8.3 [de]
      - 4.8.3.1 [de]
      - 4.8.3.2 [de]
      - 4.8.3.3 [de]
      - 4.8.3.4 [de]
    - 4.8.4 [de]
    - 4.8.5 [de]
      - 4.8.5.1 [de]
      - 4.8.5.2 [de]
      - 4.8.5.3 [de]
      - 4.8.5.4 [de]
    - 4.8.6 [de]
      - 4.8.6.1 [de]
      - 4.8.6.2 [de]
      - 4.8.6.3 [de]
      - 4.8.6.4 [de]
  - [de]
  - 4.9 [de]
    - 4.9.1 [de]
    - 4.9.2 [de]
      - 4.9.2.1 [de]
    - [de]
- 5 [de]
  - 5.1 [de]
  - 5.2 [de]
  - 5.3 [de]
  - 5.4 [de]
  - 5.5 [de]
    - 5.5.1 [de]
      - 5.5.1.1 [de]
      - 5.5.1.2 [de]
      - 5.5.1.3 [de]
      - 5.5.1.4 [de]
    - 5.5.2 [de]
      - 5.5.2.1 [de]
      - 5.5.2.2 [de]
      - 5.5.2.3 [de]
      - 5.5.2.4 [de]
    - 5.5.3 [de]
      - 5.5.3.1 [de]
      - 5.5.3.2 [de]
      - 5.5.3.3 [de]
      - 5.5.3.4 [de]
    - 5.5.4 [de]
      - 5.5.4.1 [de]
      - 5.5.4.2 [de]
  - [de]
- 6 Material Selection [de] [en]
  - 6.1 Introduction to Material Selection [de] [en]
  - 6.2 Systematic Approach [de] [en]
  - 6.3 Aids for the Selection of Materials [de] [en]
    - 6.3.1 Databases [de] [en]
      - 6.3.1.1 Database CAMPUS/Material Data Center [de] [en]
      - 6.3.1.2 Prospector Database/Ides Inc. [de] [en]
    - 6.3.2 Research [de] [en]
    - 6.3.3 Practical Laboratory Tests [de] [en]
  - 6.4 [de]
    - 6.4.1 [de]
      - 6.4.1.1 [de]
    - 6.4.2 [de]
      - 6.4.2.1 [de]
      - 6.4.2.2 [de]
      - 6.4.2.3 [de]
      - 6.4.2.4 [de]
    - 6.4.3 [de]
      - 6.4.3.1 [de]
      - 6.4.3.2 [de]
      - 6.4.3.3 [de]
      - 6.4.3.4 [de]
      - 6.4.3.5 [de]
  - Literature Chapter 6 [de]
  - 6.5 [de]
    - 6.5.1 [de]
    - 6.5.2 [de]
    - 6.5.3 [de]
    - 6.5.4 [de]
    - 6.5.5 [de]
    - [de]
- 7 Product Design [de] [en]
  - 7.1 Basic Design Rules for Injection Moulded Parts [de] [en]
    - 7.1.1 Introduction to Design Rules [de] [en]
    - 7.1.2 Rule 1: Design Minimal Wall Thicknesses [de] [en]
    - 7.1.3 Rule 2 Design Identical Wall Thicknesses [de] [en]
    - 7.1.4 Rule 3: Avoid Material Build-Up [de] [en]
    - 7.1.5 Rule 4: Provide Corners and Edges with Radii [de] [en]
    - 7.1.6 Rule 5: Design Ribs to Suit Injection Moulding Process [de] [en]
    - 7.1.7 Rule 6: Avoid Flat Surfaces [de] [en]
    - 7.1.8 Rule 7: Provide Adequate Conicity [de] [en]
    - 7.1.9 Rule 8: Avoid Undercuts [de] [en]
    - 7.1.10 Rule 9: Avoid Unnecessary Precision Machining [de] [en]
    - 7.1.11 Rule 10: Use Maximum Potential of Free Shaping [de] [en]
    - 7.1.12 Rule 11: Consider the Gate Position when Designing a Mould [de] [en]
    - 7.1.13 Rule 12: Provide Metal-Plastic Composites with a Stress-Compensating Design [de] [en]
    - 7.1.14 Rule 13: Design Plastic-Specific Holes and Cores [de] [en]
    - 7.1.15 Rule 14: Design Plastic-Specific Threads [de] [en]
    - 7.1.16 Rule 15: Optimise Moulded Parts to Suit Production Process [de] [en]
    - Literature Chapter 7.1 [de] [en]
  - 7.2 [de]
    - 7.2.1 [de]
    - 7.2.2 [de]
      - 7.2.2.1 [de]
      - 7.2.2.2 [de]
      - 7.2.2.3 [de]
      - 7.2.2.4 [de]
      - 7.2.2.5 [de]
      - 7.2.2.6 [de]
      - 7.2.2.7 [de]
    - 7.2.3 [de]
      - 7.2.3.1 [de]
      - 7.2.3.2 [de]
      - 7.2.3.3 [de]
      - 7.2.3.4 [de]
      - 7.2.3.5 [de]
    - 7.2.4 [de]
    - 7.2.5 [de]
    - [de]
  - 7.3 [de]
    - 7.3.1 [de]
      - 7.3.1.1 [de]
      - 7.3.1.2 [de]
      - 7.3.1.3 [de]
      - 7.3.1.4 [de]
      - 7.3.1.5 [de]
      - 7.3.1.6 [de]
    - 7.3.2 [de]
      - 7.3.2.1 [de]
      - 7.3.2.2 [de]
      - 7.3.2.3 [de]
      - 7.3.2.4 [de]
      - 7.3.2.5 [de]
      - 7.3.2.6 [de]
    - 7.3.3 [de]
      - 7.3.3.1 [de]
      - 7.3.3.2 [de]
      - 7.3.3.3 [de]
    - [de]
  - 7.4 [de]
    - 7.4.1 [de]
    - 7.4.2 [de]
    - 7.4.3 [de]
    - 7.4.4 [de]
    - 7.4.5 [de]
    - 7.4.6 [de]
    - 7.4.7 [de]
    - 7.4.8 [de]
    - 7.4.9 [de]
      - 7.4.9.1 [de]
      - 7.4.9.2 [de]
    - 7.4.10 [de]
    - 7.4.11 [de]
    - 7.4.12 [de]
    - 7.4.13 [de]
    - 7.4.14 [de]
    - [de]
- 8 Dimensioning of Products and Functional Elements [de] [en]
  - 8.1 Dimensioning Parameters [de] [en]
  - 8.2 Dimensioning Strategies [de] [en]
    - 8.2.1 Dimensioning Objectives and Characteristic Features of Plastic Applications [de] [en]
    - 8.2.2 Dimensioning Based on Permissible Stress [de] [en]
      - 8.2.2.1 Strength Value K as a Dimensioning Factor [de] [en]
      - 8.2.2.2 Safety Factors [de] [en]
      - 8.2.2.3 Reduction Factors [de] [en]
    - 8.2.3 Dimensioning Based on Permissible Strain [de] [en]
  - 8.3 Conventional Dimensioning [de]
    - 8.3.1 Application and Limits of Conventional Dimensioning [de] [en]
    - 8.3.2 Area Moments and Section Moduli, Radius of Gyration for Bending and Buckling [de] [en]
    - 8.3.3 Bending of Beams [de] [en]
    - 8.3.4 Torsion [de] [en]
    - 8.3.5 Shear [de] [en]
    - 8.3.6 Internal Pressure Loading of Thin-Walled Containers and Pipes [de] [en]
  - Literature Chapter 8.1 to 8.3 [de] [en]
- 9 [de]
  - 9.1 [de]
    - 9.1.1 [de]
    - 9.1.2 [de]
      - 9.1.2.1 [de]
      - 9.1.2.2 [de]
      - 9.1.2.3 [de]
      - 9.1.2.4 [de]
      - 9.1.2.5 [de]
    - 9.1.3 [de]
    - 9.1.4 [de]
      - 9.1.4.1 [de]
      - 9.1.4.2 [de]
      - 9.1.4.3 [de]
      - 9.1.4.4 [de]
    - 9.1.5 [de]
      - 9.1.5.1 [de]
      - 9.1.5.2 [de]
      - 9.1.5.3 [de]
    - 9.1.6 [de]
    - [de]
  - 9.2 [de]
    - 9.2.1 [de]
      - 9.2.1.1 [de]
      - 9.2.1.2 [de]
        
        9.2.1.2.1 [de]
        
        9.2.1.2.2 [de]
        
        9.2.1.2.3 [de]
        
        9.2.1.2.4 [de]
        
        9.2.1.2.5 [de]
        
        9.2.1.2.6 [de]
        
        9.2.1.2.7 [de]
      - 9.2.1.3 [de]
        
        9.2.1.3.1 [de]
        
        9.2.1.3.2 [de]
    - 9.2.2 [de]
      - 9.2.2.1 [de]
      - 9.2.2.2 [de]
        
        9.2.2.2.1 [de]
        
        9.2.2.2.2 [de]
        
        9.2.2.2.3 [de]
        
        9.2.2.2.4 [de]
        
        9.2.2.2.5 [de]
        
        9.2.2.2.6 [de]
        
        9.2.2.2.7 [de]
      - 9.2.2.3 [de]
    - 9.2.3 [de]
      - 9.2.3.1 [de]
      - 9.2.3.2 [de]
        
        9.2.3.2.1 [de]
        
        9.2.3.2.2 [de]
        
        9.2.3.2.3 [de]
        
        9.2.3.2.4 [de]
    - [de]
  - 9.3 [de]
    - 9.3.1 [de]
    - 9.3.2 [de]
      - 9.3.2.1 [de]
      - 9.3.2.2 [de]
      - 9.3.2.3 [de]
    - 9.3.3 [de]
      - 9.3.3.1 [de]
    - [de]
  - 9.4 [de]
    - 9.4.1 [de]
    - 9.4.2 [de]
    - 9.4.3 [de]
    - 9.4.4 [de]
    - 9.4.5 [de]
      - 9.4.5.1 [de]
      - 9.4.5.2 [de]
      - 9.4.5.3 [de]
    - 9.4.6 [de]
    - [de]
  - 9.5 [de]
    - 9.5.1 [de]
    - 9.5.2 [de]
    - 9.5.3 [de]
    - 9.5.4 [de]
    - 9.5.5 [de]
    - 9.5.6 [de]
    - 9.5.7 [de]
    - 9.5.8 [de]
    - [de]
  - 9.6 [de]
    - 9.6.1 [de]
    - 9.6.2 [de]
    - 9.6.3 [de]
    - [de]
- 10 [de]
  - 10.1 [de]
  - 10.2 [de]
    - 10.2.1 [de]
      - 10.2.1.1 [de]
      - 10.2.1.2 [de]
    - 10.2.2 [de]
      - 10.2.2.1 [de]
      - 10.2.2.2 [de]
      - 10.2.2.3 [de]
    - 10.2.3 [de]
      - 10.2.3.1 [de]
      - 10.2.3.2 [de]
    - 10.2.4 [de]
      - 10.2.4.1 [de]
      - 10.2.4.2 [de]
      - 10.2.4.3 [de]
  - [de]
  - 10.3 [de]
    - 10.3.1 [de]
      - 10.3.1.1 [de]
      - 10.3.1.2 [de]
      - 10.3.1.3 [de]
      - 10.3.1.4 [de]
    - 10.3.2 [de]
      - 10.3.2.1 [de]
      - 10.3.2.2 [de]
    - 10.3.3 [de]
      - 10.3.3.1 [de]
      - 10.3.3.2 [de]
      - 10.3.3.3 [de]
      - 10.3.3.4 [de]
      - 10.3.3.5 [de]
      - 10.3.3.6 [de]
      - 10.3.3.7 [de]
      - 10.3.3.8 [de]
      - 10.3.3.9 [de]
      - 10.3.3.10 [de]
      - 10.3.3.11 [de]
    - 10.3.4 [de]
      - 10.3.4.1 [de]
      - 10.3.4.2 [de]
      - 10.3.4.3 [de]
    - 10.3.5 [de]
  - 10.4 [de]
  - [de]
- 11 Tolerances of Plastic Products [de] [en]
  - 11.1 Tolerance Issues and Causes for Dimensional Variations of Plastic Products [de] [en]
    - 11.1.1 Tabular Overview of Causes for Dimensional Variations of Plastic Products [de] [en]
    - 11.1.2 Causes for Dimensional Variations in the Manufacture of Plastic Products [de] [en]
      - 11.1.2.1 Influence of Material [de] [en]
      - 11.1.2.2 Influence of Design [de] [en]
      - 11.1.2.3 Influence of Tooling [de] [en]
      - 11.1.2.4 Influence of Manufacturing Process [de] [en]
    - 11.1.3 Changes of Dimensions and Geometry of Plastic Applications under Operating Conditions [de] [en]
      - 11.1.3.1 Influence of Temperature [de] [en]
      - 11.1.3.2 Influence of Surrounding Media [de] [en]
      - 11.1.3.3 Influence of Post-Mould Shrinkage [de] [en]
      - 11.1.3.4 Influence of Mechanical Load [de] [en]
      - 11.1.3.5 Influence of Wear [de] [en]
  - 11.2 Tolerance System [de] [en]
    - 11.2.1 Terminology [de] [en]
    - 11.2.2 Important Tolerance Standards for All Materials Including Plastics [de] [en]
      - 11.2.2.1 The Material-Independent ISO System of Tolerances [de] [en]
      - 11.2.2.2 General Tolerances for Metal Parts [de] [en]
  - 11.3 Tolerance Standards for Plastic Products [de] [en]
    - 11.3.1 DIN 16 901 Concerning the Tolerancing of Parts Produced by Injection Moulding. Injection-Compression Moulding, Transfer Moulding and Pressing (Withdrawn by DIN in 2009) [de] [en]
    - 11.3.2 DIN 16742 Moulded Plastic Parts - Tolerances and Acceptance Conditions [de] [en]
    - 11.3.3 Forms for the Use of DIN 16742 [de] [en]
  - Literature Section 11 [de] [en]
- 12 Costing [de] [en]
  - 12.1 Calculation of Manufacturing Costs of Injection Moulded Parts [de] [en]
    - 12.1.1 Introduction to Costing [de] [en]
    - 12.1.2 Structure of Manufacturing Costs [de] [en]
    - 12.1.3 Calculation of Purchase Prices Taking Overheads and Profits into Account [de] [en]
    - 12.1.4 [de]
      - 12.1.4.1 [de]
      - 12.1.4.2 [de]
      - 12.1.4.3 [de]
      - 12.1.4.4 [de]
      - 12.1.4.5 [de]
      - 12.1.4.6 [de]
    - 12.1.5 Costing with the Online Costing Tool [de] [en]
      - 12.1.5.1 General Information of the Online Costing Tool [de] [en]
      - 12.1.5.2 Section: General Information [de] [en]
      - 12.1.5.3 Section: Manufacturing Costs of an Injection Moulded Part [de] [en]
      - 12.1.5.4 Section: Overview of Product Costs Including Overheads and Profit [de] [en]
      - 12.1.5.5 Section: Graphical Evaluation [de] [en]
      - 12.1.5.6 Detailed Documentation of Results [de] [en]
  - Literature Chapter 12 [de] [en]
- 13 [de]
  - 13.1 [de]
  - 13.2 [de]
    - 13.2.1 [de]
    - 13.2.2 [de]
    - 13.2.3 [de]
    - 13.2.4 [de]
    - 13.2.5 [de]
    - 13.2.6 [de]
  - 13.3 [de]
  - 13.4 [de]
    - 13.4.1 [de]
    - 13.4.2 [de]
    - 13.4.3 [de]
    - 13.4.4 [de]
    - 13.4.5 [de]
  - [de]
- 14 [de]
  - 14.1 [de]
  - 14.2 [de]
    - 14.2.1 [de]
    - 14.2.2 [de]
    - 14.2.3 [de]
    - 14.2.4 [de]
    - 14.2.5 [de]
    - 14.2.6 [de]
      - 14.2.6.1 [de]
      - 14.2.6.2 [de]
  - [de]
- 15 [de]
  - 15.1 [de]
  - 15.2 [de]
  - 15.3 [de]
    - 15.3.1 [de]
    - 15.3.2 [de]
    - 15.3.3 [de]
    - 15.3.4 [de]
    - 15.3.5 [de]
  - [de]
- 16 [de]
  - 16.1 [de]
  - 16.2 [de]
    - 16.2.1 [de]
    - 16.2.2 [de]
    - 16.2.3 [de]
    - 16.2.4 [de]
    - 16.2.5 [de]
    - 16.2.6 [de]
    - [de]
  - 16.3 [de]
    - 16.3.1 [de]
    - 16.3.2 [de]
    - 16.3.3 [de]
    - 16.3.4 [de]
    - 16.3.5 [de]
      - 16.3.5.1 [de]
      - 16.3.5.2 [de]
      - 16.3.5.3 [de]
    - 16.3.6 [de]
    - [de]
  - 16.4 [de]
    - 16.4.1 [de]
    - 16.4.2 [de]
    - 16.4.3 [de]
    - [de]

Product Design

Dr. Sigrid Brinkmann, Prof. Dr.-Ing. Thomas Brinkmann, Andreas Dörner, Veronika Hackl, Fabian Hellwasser, Florian Pelzl, Dr.-Ing. Wolfgang Schlegel, Timo Schuler, Josef Stubenrauch, Elisabeth Winterstein

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Product development with 15 rules

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Content:

(For details of the chapter see also the table of contents on the left)

You buy an access to the whole German (7.1 until 7.4) and English (7.1) text of chapter 7.

The following parts of chapter 7 "Product Design" are available in English [en] and German [de]. The other chapters are only available in German.

English 7.1:

Detailed discussion of all 15 rules

A good mold part requires a material, process and tool-appropriate design. Moldings which are not optimized with regard to these requirements can not be produced with a well-designed tool. The design of good moldings requires compliance with fundamental basic rules. These are described in detail in the article and are illustrated by numerous examples.

Basic design rules for injection molded parts
Introduction to Design Rules

Rule 1: Design Minimal Wall Thicknesses [de] [en]
Rule 2: Design Identical Wall Thicknesses [de] [en]
Rule 3: Avoid Material Build-Up [de] [en]
Rule 4: Provide Corners and Edges with Radii [de] [en]
Rule 5: Design Ribs to Suit Injection Moulding Process [de] [en]
Rule 6: Avoid Flat Surfaces [de] [en]
Rule 7: Provide Adequate Conicity [de] [en]
Rule 8: Avoid Undercuts [de] [en]
Rule 9: Avoid Unnecessary Precision Machining [de] [en]
Rule 10: Use Maximum Potential of Free Shaping [de] [en]
Rule 11: Consider the Gate Position When Designing a Mould [de] [en]
Rule 12: Provide Plastic-Metal Composites With a Stress-Compensating Design [de] [en]
Rule 13: Design Plastic-Specific Holes and Cores [de] [en]
Rule 14: Design Plastic-Specific Threads [de] [en]
Rule 15: Optimise Moulded Parts to Suit Production Process [de] [en]

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