MATL07019 2022 Plastic Part Design
Full Title
Plastic Part Design
Transcript Title
Plastic Part Design
Code
MATL07019
Attendance
N/A %
Subject Area
MATL - 0722 Materials WD/PPR/PLAS/GL
Department
MECT - Mechatronics
Level
07 - Level 7
Credit
10 - 10 Credits
Duration
Semester
Fee
€
Start Term
2022 - Full Academic Year 2022-23
End Term
9999 - The End of Time
Author(s)
David Mulligan, Douglas Marques
Programme Membership
SG_EPOLP_J07 202200 Bachelor of Engineering in Polymer Process Engineering
SG_EPOLA_J07 202400 Bachelor of Engineering in Polymer Process Engineering
SG_EPOLY_S07 202400 Certificate in Polymer Processing
SG_EPLYP_J07 202400 Bachelor of Engineering in Polymer Processing
Description
This module covers the principles and materials of plastic part design to ensure high quality parts for polymer and medical device sector.
Learning Outcomes
On completion of this module the learner will/should be able to;
1.
Distinguish the properties of crystalline and amorphous materials to include appearance, flow, chemical resistatnce, shrinkage and deformation levels.
2.
Explain structural design features such as wall thickness, ribs and bosses and their effects on weight and cooling requirements
3.
Analyse injection mould design constraints to include part removal methods, draught angles, surface finish, and undercuts
4.
Critically evaluate the injection moulding process with reference to wall thickness variation, shrinkage, deformation and gating points and their influence on the options at the part design stage
5.
Design plastic parts giving due consideration to the characteristics of materials used, and production methods including injection, compression and blow moulding, extrustion and thermoforming
6.
Design plastic parts taking advantage of the unique flow characteristics of the injection moulding process to include shear heating effects and melt viscosity changes throughout the injection moulding process.
7.
Demonstrate an understanding of the documentation requiremnts for the validation for a plastic part design.
Teaching and Learning Strategies
Material will be delivered via an online teaching approach and will also include a number of practical sessions delivered by first polymer in Athlone
Module Assessment Strategies
Learning outcomes will be assessed through a varied structure of assignments, based on the following:
QUESTIONNAIRES: Multiple choice assessment of theory. Presented on an open book format with extended deadline of delivered, this format is to be implemented in diverse stages of the academic term. The educational goal is to assess critical, thinking, allow cross reference of content, and construction of understanding. Although with individual delivery/submission, task may be approached as a group activity, depending on quorum and initiative of student group.
PROJECT: Design-based assignment. Presented as a semester-long assignment, this individual activity aims to explore the rationale behind decision making. The design perspective is targeted at development of plastic parts and limited by polymer processing constraints. The project is an individual activity with individual delivery and long development. Design component of the proposed activity is benefited if students had previously completed Polymer Tooling Design and/or Computer Aided Design & Modelling, but completion of task is not dependent on previous experience. Theoretical component of the proposed activity aims to integrate critical thinking, decision making, and understanding of theory exposed during session through academic term.
FINAL EXAM: summative evaluation of learning for understanding. Theoretical assessment presented in open-book format with limited time (ideally 3 hours) for completion. Does not require proctoring, as assessment explores content assimilation and development of connections between contents along the academic term. Communication skills and rationale development are assessed as well as learning outcomes.
Repeat Assessments
Repeat Exams and resubmission of project
Indicative Syllabus
An Introduction to Plastic Materials
- Historical Development
- Fundamental Concepts
- Molecular Weight
- Repeat Unit Structure
- Morphology
- Effect of Additives
- Mechanical Property Overview
- Flow Property Overview
- Advantages of Plastic Materials
- Limitations of Plastic Materials
Review of Injection Molding Equipment
Review of the Injection Molding Process
Review of Injection Molds
- Design Considerations for Injection Molded Parts
- Mold Filling Considerations
- Effect of Gate Location and Type
- Molecular and Fiber Orientation
- Mold Filling Pressure Drop
- Flow Leaders and Flow Hesitation
- Mold Filling Simulations
- Runner Balancing and Family Molds
- Weld or Knit Lines
- Shrinkage and Warpage Considerations
- Part Ejection Considerations
Mechanical Behavior of Plastic Materials
Approaching Plastic Product Development
- Establishing End Use Requirements
- Conceptual Design
- Initial Candidate Material Selection Procedures
- Design Based Upon the Materials Selected
- Final Materials Selection
- Manufacturing Related Design Modifications
- Prototyping and Testing
- Production Tooling and Manufacturing
- Plastic Part Prototyping Techniques
- Assembly Techniques for Injection Molded Parts
Coursework & Assessment Breakdown
Coursework & Continuous Assessment
50 %
End of Semester / Year Formal Exam
50 %
Coursework Assessment
| Title | Type | Form | Percent | Week | Learning Outcomes Assessed | |
|---|---|---|---|---|---|---|
| 1 | Project | Project | Project | 30 % | Week 14 | 2,3,4,5,6 |
| 2 | Questionnaire | Coursework Assessment | Multiple Choice/Short Answer Test | 20 % | Week 6 | 5,6,7 |
End of Semester / Year Assessment
| Title | Type | Form | Percent | Week | Learning Outcomes Assessed | |
|---|---|---|---|---|---|---|
| 1 | Exam Paper | Final Exam | Assessment | 50 % | End of Term | 1,2,3,4,5,6,7 |
Full Time Mode Workload
| Type | Location | Description | Hours | Frequency | Avg Workload |
|---|---|---|---|---|---|
| Practical / Laboratory | Not Specified | Practicals | 20 | Twice Per Semester | 2.67 |
Total Full Time Average Weekly Learner Contact Time 2.67 Hours
Online Learning Mode Workload
| Type | Location | Description | Hours | Frequency | Avg Workload |
|---|---|---|---|---|---|
| Online Lecture | Not Specified | Online Lecture | 1 | Weekly | 1.00 |
Total Online Learning Average Weekly Learner Contact Time 1.00 Hours
Required & Recommended Book List
Recommended Reading
2010-03-01 Plastic Part Design for Injection Molding 2E: An Introduction Hanser
ISBN 1569904367 ISBN-13 9781569904367
2010-03-01 Plastic Part Design for Injection Molding 2E: An Introduction Hanser
ISBN 1569904367 ISBN-13 9781569904367
The goal of the book is to assist the designer in the development of parts that are functional, reliable, manufacturable, and aesthetically pleasing. Because injection molding is the most widely used manufacturing process for the production of plastic parts, a full understanding of the integrated design process presented is essential to achieving economic and functional design goals. This book features over 425 drawings and photographs. Contents: Introduction to Materials. Manufacturing Considerations for Injection Molded Parts. The Design Process and Material Selection. Structural Design Considerations. Prototyping and Experimental Stress Analysis. Assembly of Injection Molded Plastic Parts. Conversion Constants.