Plastic Manufacturing Methods Identifying Features

1. Plastic Manufacturing Methods Identifying Features Product Design

2. Modern Manufacturing Methods An understanding of how things are manufactured in an industrial context is vital to the successful outcome of bringing a new product to the marketplace. Modern manufacturing methods offer great flexibility and variety of choice to designers. Complex curvilinear shapes and forms are much easier to manufacture than ever before. Surface textures and small detail are becoming common practice as methods of mould making embrace new technology and production methods. However, there are still restrictions to the common working practices that designers must observe in the design of any mass-produced product. A close examination of an everyday product will reveal certain similarities. A few of the design features relating to plastic casings are outlined in the following list: Split Lines These occur naturally when two parts of the outside casing of a product join together. One part of the casing will locate inside the other part. Often leaving a small groove running along the length of the product. Split lines are usually found at the widest part of the product.

3. Break lines These appear as lines or grooves on the surfaces of the parts of a product. They are used to divide up otherwise featureless areas or to add details or features to one part of the product. On large flat surfaces, break lines can be used to disguise distortions that may appear as a result of manufacturing. Tapered sides These are necessary parts of any components that have to be injection moulded. The tapered sides allow these parts to be easily removed from moulds. Tapers are often as little as 1°.

4. Radius corners These allow molten plastic to flow easily around moulds. They strengthen corners and allow for parts to be easily removed from moulds. Webs These are usually internal features which are used to add strength or support to parts. On some products, webs are visible on the outside and so can be used as a feature.

5. Surface textures Textures or patterns can be used on the surface of any mass-produced product. They are produced by a process called spark erosion, which is a method of texturing the inside surface of moulds. Other considerations include the location of injection and ejection points (Which appear as small blemishes on the surface of products). They are usually designed to be hidden on parts that are not easily seen or are not normally looked at. When designing for manufacture it makes good sense to examine and analyse how other products that use similar manufacturing processes are made.

6. Pupil assignment – Analysis of Polymer Cased products Step One: Taking one of the available products, look carefully at the internal and external plastic body / casing. Identify mass production design features form your product. Step Two: Once features have been identified, list them on the lined A4 paper which is handed out. Using the information which was contained in the PowerPoint explain the purpose or otherwise for each feature identified. Step Three: Using your selected product take two or three digital photographs of it. Make sure the photographs capture both the internal and external features which you have already indicated in Step One & Two. Step Four: Transfer images from floppy disk into your product design folder. Step Five: Create a PowerPoint template and insert your images onto a suitable background. Step Six: Develop a PowerPoint presentation, showing on the product images the areas were features exist and annotate accordingly.