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The goal of the book is to assist the designer in the development of parts that are functional, reliable, manufacturable, and aesthetically pleasing. Since 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. Features over 425 drawings and photographs.
Design and Manufacture of Plastic Components for Multifunctionality: Structural Composites, Injection Molding, and 3D Printing presents the latest information on how plastics manufacturers are increasingly being driven towards carbon emission reduction, lightweighting, and cost savings through process integration. These technologies have the potential to revolutionize future products with built-in functionality such as sensors, smart packaging, and damage detection technology for everything from milk bottles and salad packaging to automotive bumpers and plane fuselages. This book introduces the three core manufacturing methods for multifunctional materials, composites, injection molding, and 3D printing, all processes facing challenges for the implementation of new technology. Users will find a book that brings together both process and material advances in this area, giving process engineers, designers, and manufacturers the information they need to choose the appropriate material and process for the product they are developing. Provides an introduction to the latest technologies in the area of multifunctionality, enabling engineers to implement new breakthroughs in their own businesses Gives an understanding of the processes that need to be considered in both design and manufacture of future devices, while using materials from a broader palette than used in existing manufacturing processes Includes best practice guidance and flow charts to aid in material and process selection Covers revolutionary future products with built-in functionality such as sensors, smart packaging, and damage detection technology for everything from milk bottles and salad packaging to automotive bumpers and plane fuselages
This book is for the industrial designer interested in the applications of plastics in products and industry. It explains how different plastics are processed, and it contains extensive examples of common and unusual plastic components and products with an explanation of how they are manufactured. Every year, more products are being replaced or augmented by the same product made from plastic, and this trend has resulted in much debate about the effectiveness of plastic replacements. Today's plastics can be designed to operate in all weather conditions and chemical surroundings. They can be economically produced for short run part production or readily adapted to high quantity production, and they can be cut, glued, tapped, or machined by traditional methods to suit design needs. Explains how to choose the best processing method, what fastening or joining methods can be used, and how to use the characteristics of a plastic to judge its suitability for an application. Covers all major contemporary molding processes. Discusses, in detail, important topics such as surface finish and special effects.
This book provides a simplified and practical approach to designing with plastics that funda mentally relates to the load, temperature, time, and environment subjected to a product. It will provide the basic behaviors in what to consider when designing plastic products to meet performance and cost requirements. Important aspects are presented such as understanding the advantages of different shapes and how they influence designs. Information is concise, comprehensive, and practical. Review includes designing with plastics based on material and process behaviors. As de signing with any materials (plastic, steel, aluminum, wood, etc.) it is important to know their behaviors in order to maximize product performance-to-cost efficiency. Examples of many different designed products are reviewed. They range from toys to medical devices to cars to boats to underwater devices to containers to springs to pipes to buildings to aircraft to space craft. The reader's product to be designed can directly or indirectly be related to product design reviews in the book. Important are behaviors associated and interrelated with plastic materials (thermoplastics, thermosets, elastomers, reinforced plastics, etc.) and fabricating processes (extrusion, injec tion molding, blow molding, forming, foaming, rotational molding, etc.). They are presented so that the technical or non-technical reader can readily understand the interrelationships.
Hollow plastic parts range in size from small unit dose liquor bottles, doll heads and syringe bulbs to large gasoline tanks, pallets, and playground equipment. Designers and design engineers are often familiar with one way of making these parts but may not be aware of other methods that may offer greater design and performance flexibility. The book provides comprehensive design and manufacturing comparisons of three major methods - blow molding, rotational molding and twin-sheet thermoforming- as well as an overview of other methods used to produce hollow plastic parts. Not only will the seasoned designer be able to determine the advantages and limitations of specific technologies, but the newcomer will also be able to quickly select the best manufacturing method for his particular hollow product.
This overview assists the designer in the development of parts that are functional, reliable, manufacturable, and aesthetically pleasing. Since injection molding is the most widely used manufacturing process for plastic parts, a full understanding of the integrated design process presented is essential to achieving economy and functional design.
Designing Successful Products with Plastics: Fundamentals of Plastic Part Design provides expert insight into design considerations required to bring a concept product or part through design and ready-for-production. The book shows how integrating four key choices—materials, processes, tooling and design—in every design decision allows the designer to fully vet and optimize the design. Rather than focusing on design rules and engineering equations used during product development, the emphasis of the book is on what the designer needs to consider during the early conceptual visualization stages, and in the detailed stages of the design process. This approach will bridge the gap between the industrial designer, tasked with the ‘big picture’ product design and use, and the part designer, tasked with the detailed plastic part design for manufacture. Useful to both experienced and novice designers, this book brings valuable design process information through specific examples, enabling designers and engineers in the plastics industry to effectively use the available technical information to successfully design and manufacture new products. Bridges the gap between the industrial designer working on product design and use, and the part designer working on detailed part design for manufacture Enables designers to establish a solid foundation for new product development on the ‘four pillars’ of the process: materials, processes, tooling, and design Provides a hierarchy and roadmap through creative product design and implementation, so engineers can translate a product from creative concept through to realization and commercialization
"Designing Plastic Parts for Assembly" provides an excellent tool for both seasoned part designers and novices to the field, facilitating cost effective design decisions and ensuring that the plastic parts and products will stand up under use. The detailed yet simplified discussion of material selection, manufacturing techniques, and assembly procedures will enable the reader to evaluate plastic materials and to adequately design plastic parts for assembly. The book describes good joint design and implementation, the geometry and nature of the component parts, the types of load involved, and other basic information necessary in order to work successfully in this field. Throughout, the treatment is practice-oriented and focused on everyday problems and situations. The 7th edition introduces a completely new chapter on overmolding and in-mold assembly, as well as a new chapter on bonding, including accompanying examples. Laser molding and ultrasonics coverage are also brought up to date, with illustrative case histories. Contents: - Understanding Plastic Materials - Understanding Safety Factors - Strength of Materials for Plastics - Nonlinear Considerations - Assembly Techniques for Plastics - Press Fitting - Living Hinges - Snap Fitting - Bonding - In-Mold Assembly.
How easy life would be if only moldings were the same size and shape as the mold. But they never are, as molders, toolmakers, designers and end users know only too well. Shrinkage means that the size is always different; warpage often changes the shape too. The effects are worse for some plastics than others. Why is that? What can you do about it? The Handbook of Molded Part Shrinkage and Warpage is the first and only book to deal specifically with this fundamental problem. Jerry Fischer’s Handbook explains in plain terms why moldings shrink and warp, shows how additives and reinforcements change the picture, sets out the effect of molding process conditions, and explains why you never can have a single ‘correct’ shrinkage value. It goes on to demonstrate how to alleviate the problem through careful design of the molded part and the mold, and by proper material selection. It also examines computer-aided methods of forecasting shrinkage and warpage. And most important of all, the Handbook gives you the data you need to work with. Authoritative and rooted in extensive industrial experience, the expert guidance contained in this handbook offers practical understanding to novices, and new insights to readers already skilled in the art of injection molding and mold making Contains the answers to common problems and detailed advice on how to control mold and post-mold shrinkage and warpage Case Studies illustrate and enrich the text; Data tables provide the empirical data that is essential for success, but hard to come by