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plastic product design
plastic product design I plastic engineering I plastic basics
A simple mold holds the basic plastic injection rules. The molds are made of steel and are manufactured using machining. In the picture, the blue area is a cut of a simple product. In a pattern, this space is actually air or space between the male nold and the female mold. The plastic is crammed in at the filling point, filling the empty space. After the injection, the female mold moves back and the product comes out of the mold. The direction in which the mold moves during extraction is called the direction of extraction
plastic product design I plastic basics I slider mold
Sometimes the simple product contains areas of handles, grooves and pipes that do not face the direction of extraction. These areas are called an undercuts. Undercut is any element that interferes with the mold to open at the angle of the extraction. It is impossible to extract such a product in a simple mold because these plastic would be stuck and locked geometrically in a mold. Therefore, steel parts are added in the mold. those move sideways before the usual mold moves back in the direction of the extraction.
plastic product design I plastic basics I modls with sliders
The parts that move to the sides after the injection are referred to as sliders. The slider moves in a slot as on a track in the mold. The design of the mold that contains sliders takes longer and involves adding parts due to complexity. Thus, a template that contains sliders will be more expensive to the customer. In the picture, you can see a slider with a yellow mark showing the direction of its journey. You can see the whole mold of the product made of two large parts.
plastic industrial design I plastic basics I injection molds
In the picture in front of us, two parts of the mold are seen move sideways as part of a four-part mold. Male, female, and two sliders moving sideways in the direction of the arrows, creating what appeared to be a thread. The product infront of us, appears when it is still "mounted" on the male part while the other parts are open. In the industrial design studio, we take into account all the parameters related to mechanical design when designing a product.
plastic industrial design I plastic basics I slider marks
In the finished product, especially on the inside, you can see scars and witness lines. Residues that tell about the flow of a viscous material flows in a steel cavity. When a slider is in a mold, its movement will scrape off the surface of plastics that has not yet dried in the mold. In the photo you can see a frame stretching at the foot of "Snap". It should be noted that if there was no slider, the product could not be extracted because there is an undercut at the top of the snap.
product design I plastic basics I PCB
Quntz Product Designers is a studio specializing in design, as well as mechanical design. To match the electronic components to the design, the PCB was adapted to the shape of the shell. The pins on the sides of the PCB, in addition to being a connection between the base of the product and the shell, fix the PCB. You can see them in the picture, marked in yellow.
plastic product design I plastic engineering I areas in mold
The picture before us focuses on the main plastic shell of the product. You can see its exterior. There are several types of plastic connectors. You can see that the "cap" which is the upper round part connects to the main shell by snaps. Snaps turn outward so there is no Undercut. Although, you can see a small slot for which a cart has been created in a format. (Marked in square in lower right image). You can see the slider marks in the mold. The slider tapped the plastic while it was a viscous fluid in the mold. In the big picture on the left, you can see that the central part contains openings that catch the snaps of the cap. The same openings form internal, create meeting areas between the steel parts in the mold. These areas are called "shut off".
plastic industrial design I plastic engineering I areas in mold
An internal look at an optical element in the product. We designed the product, so that on the outside, the surface of the optical panel will blend into that of the white plastic. (Top images). From the inside, the pattern is not as smooth as the outside. The white plastic contains shut offs that accommodate the snaps of the transparent plastic. The structure of the snaps of transparent plastic is seen in the lower left picture. Also, can you identify the area containing a sloders? Look at the lower-right picture. You can see the steel scars on the plastic surface
plastic product design I plastic engineering I wall thickness
A cross-sectional look at the simulation of a communication product that we designed here, in Quntz , product design studio. Reinforcing ribs ensure a product that is resistant to various forces. A certain size plastic product is committed to reinforcement ribs. The ribs are built so that they can be extracted at the angle of extraction. ribs Thickness shall not exceed 2/3 of the nominal thickness Otherwise, the plastic will collapse inward during cooling and create sink marks on the surface. The appropriate thickness of the reinforcement ribs ensures a uniform flow of plastic in the mold
plastic product design I plastic engineering I shut off
Simulation of a part of a communication product that we designed here in Quntz Product Design studio. You can notice the through holes in different areas of the product. Areas of shut offs. Also regional "mouse hole" that do not require a slider. In addition, the cavity surrounding the product. This is a cavity is for the laying of a rubber band that we are planning as well. The rubber band is designed for sealing.
plastic product design I plastic design I slider in the mold
Simulation of part of a product we designed. In the picture you can see all those holes that do not face to the direction of the extraction. These holes require moving parts in the mold. sliders. Quntz product designers, international experts in the development of innovative products from initial design to advanced mechanical design and preparation and accompaniment of mass production. Everything is done in our studio, under one roof.
plastic product design I plastic design I mechanical design
The product which injected from plastic is constructed as a uniform thickness to ensure uniform flow of the liquid plastic in the mold and to prevent distortions and suction marks on the plastic surface resulting from uneven cooling due to excessive plastic thickness. Another reason for planning a plastic product as a shell is to save material and weight and the ability of the product to function as an empty housing container for storage or electronic circuits, etc. The right shapes for the design of a plastic part with a relatively thin wall thickness are shown on the left side of the picture. You cannot create a full part as in the right picture below because of all the above mentioned values, but only a thin wall thickness product and reinforcement ribs that follow the product volume.
plastic product design I plastic design I plastic corners
Quntz Product Designers, an industrial design firm specializing in designing plastic parts. The encounter between the sides of the plastic part must be smooth and "flowing" there is no room for sharp corners on the inside of the part and the outside. Encounter walls must contain radius and maintain uniform wall thickness. In other words, the outer radius must be proportional to the inner radius. As for the wall itself, if it has variable thickness, which itself is not ideal, we will create a diagonal transition between the different surface areas and soften the transition.
plastic product design I mechanical design I sink marks
Plastic is very sensitive to faulty planning and is not forgiving. This is expressed in the fact that it tends to leave distortions and deformations on the surface. Only a quality product design office that understands "in-depth planning" can perform the job properly. The picture shows a product on one side showing shallow reinforcement rings. They are also seen on the other side of the product. It seems that these rings are too thick relative to the nominal thickness of the product and therefore there are sinkmarks on the other side. Proper planning is key to the success of a product that looks great.
plastic design I mechanical design I appropriate design
There are iron rules in plastic design. A whole world of laws gives us the ability to design an impeccable product. On the right side of the picture we can see the correct ratio between the internal reinforcement rib and the thickness of the nominal wall of the product. In order to extract mold seamlessly and without leaving any marks, we should not use an angle less than 3 degrees, which is more important when it comes to a surface area with a roughness that causes the friction to erode the texture, The thickness of the rib should be 2/3 or less than the nominal wall thickness, the height of the reinforcement rib shall be no more than X10 times the wall thicknes's height.
plastic design I mechanical design I burn marks
Dimensions of internal elements in plastics are correlated to the completeness of a product. In the picture in front of us, the edges of the inner reinforcement ribs appear as they collapsed in the mold, burned or twisted. Usually, when it comes to a large product with a large amount of reinforcement, the prototype will not come out perfect on the first time. It turns out that the reinforcement ribs in certain places were too high and too narrow.
product design I mechanical design I sink marks covering
the surface quality is important to the success of a product. it's important that there will be no trace of the deformations caused by the reinforcement ribs. In the pictures on the left you can see that the surface is rough. The roughness, beyond its aesthetics, hides the plastic sinkmarks created at the reinforcement ribs area. On the right side of the picture, images from the design process. On the surface, we run a kind of ditch where the plastic is thicker as a result of internal reinforcement.
product design I mechanical design I parting line
Parting line. The birthmarks of the plastic part will also appear in the appearance of the parting lines. The same lines that we find on the margins of plastic products. In the picture in front of us, the dividing line lies in the middle of rounded margins. A design that allows rounded and pleasant margins to the touch of the user. In the picture below, it is possible to see that a two-part diagram in the red-marked pattern forms a line of separation in a rounded border like the one we planned in the industrial design studio on the right. Above left picture, it seems the design of the parting line on the sharp edge of the plastic part wall. For the most part, planning such an edge will not be pleasant to touch and sharp.
product design I mechanical design I angles
In the diagram before us, it is possible to discern different values that show how to correctly design a plastic part. Notice the shut off. With shut off, we can design openings that do not face towards the angle of extraction without the need for sliders. There is a small opening to the contact between the two pieces of steel molds. In order to produce a proper frictionless contact, this area requires us to design at a minimum of 5 degrees.
industrial design I mechanical design I shut off design
With SHUT OFF, we can design a hole that does not face the direction of extraction without the help of sliders in the mold Because the hole is built so that if we look at it from the extraction direction we will still recognize the opening. Which means that the steel parts will meet in the mold. However, this area should have a relatively high extraction angle. At least 5 degrees
industrial design I mechanical design I slider design
"Birth marks" in the product are also visible after the injection. In the illustration before us, two openings are visible. One, on the right, is a mouse hole, which does not require special treatment in the mold. The left side shows a side hole that does not face the direction of extraction. We will need a slider in the mold the move to the to the side and create contact with the plastic flowing in the mold. Therefore, the slider will be in contact with the flowing and cooling plastic in the mold and "paint" its boundaries (see here in the illustration, marked in green).
plastic product design I mechanical design I boss design
Correct design of the bosses: Quntz Product Designers is Israel's leading designer and developer of plastic products. Under one roof, you will be equipped with an innovative and planned product and save costs. The picture here shows a boss's design. Boss is a cold connector between two product shells. Usually a boss will contain a hole to insert a screw and an opposite boss containing an insert for the screw. Indeed, like the reinforcement ribs, poor boss design will easily lead to plastic deformities. Avoid attaching the boss to the plastic wall for example. Also, in favor of structural strength, the boss should be pinned to the reinforcement rib. A boss-thickness meeting will have a radius and sometimes, as in the picture, the boss will be in the center of an area, where the wall thickness is slightly smaller to facilitate plastic flow in the mold and to improve structural strength.
plastic design I mechanical design I boss design
In the process of developing a plastic product, we show a cross section of the product for you in the boss area at the center of the reinforcement rib. You can see that the bottom of the boss is slightly below the nominal internal height of the plastic part. In addition, there is an angle of extraction and radius in the area of encounter with the wall thickness. Quntz product designers, industrial design experts that provide costumers with comprehensive solutions of product development and full turnkey advice.
plastic product design I mechanical design I euro pallet
Quntz Product designers give their customers, comprehensive solutions and enable them to develop a product with economic values. Here is a product designed with a high angle of extraction, so that NESTING will be applied. The high-quality product packaging and high-cost storage saves storage costs and high storage real estate, and the base dimensions of the product are designed to accommodate storage and transport within "Europeallet" standards, a standard for storage and international transport that saves costs.
plastic product design I industrial design I nesting
Quntz Product design studio, think ahead when designing a product. We look at different aspects when we approach planning. For example, in the location of rib reinforcement we are considered the ultimate position that combines structural strength and the ability of one product to "push" the surface of another product during NESTING. This will give us a perfect product that meets stringent storage requirements.
plastic product design I industrial design I plastic flow
In the picture, we can see how we "map" the grid of the reinforcement ribs so that it flows along with the plastic. Since plastic flows in a pattern at a certain point, it is important that each reinforcement element will be oriented toward the plastic flow in the mold. Our design firm's experience in designing our plastic product motivates us to lead the product development market in Israel.
mechanical design I industrial design I plastic flow
in the developing of a plastic furniture or a large plastic consumer product, sometimes the prototypic is a stage of experimentation. The manufacturer produced a product with holes, deformations and burnmarks. Following our findings, we made changes to the mold design in order to completely eliminate all defects discovered after the production of the prototype, and our experience in the industrial design studio led us to eliminate all the problems after only one test.
mechanical design I product design I plastic flow design
In this picture, we can see how we overcome the prototypes problems by changing the heights of the surface and dividing it into different "planes" around reinforcement areas and reinforcement ribs, preventing distortions and sinkmarks on the surface of the product. Years experience in the plastics field, has brought Quntz Industrial Design firm to be the market leader in the field of complete product development. Design and mechanical design of products under one roof.
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