Protomold - Design For Mold Ability

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Designing
for moldability
A quick-reference user guide for rapid
injection molding for engineers and designers
• 2nd edition •
Real Parts. Really Fast.

Proto Labs, Inc. 5540 Pioneer Creek Drive, Maple Plain, MN 55359 877.479.3680 WWW.PROTOMOLD.COM
DESIGNING FOR MOLDABILITY
TABLE OF CONTENTS
What is injection molding?
What is injection molding 2
What is Rapid Injection Molding 3 1 The hopper is loaded with the plastic stock material.
Applications of Rapid
Injection Molding 3 2 A heated barrel is used to melt the beads into a molten form.
Wall thickness 4
Cored Geometry 4 3 A screw apparatus is used to inject the polymer into a mold.
Recommended wall thickness 5
Warp 5
4 The part cools and solidifies.
Sharp corners 6
5 The mold is opened and the part ejected.
Ribs 6
Bosses 7
Draft 7
Core-cavity 8
Deep (milling) impact 8
Texture 8
Straight pull mold 9
Side actions 9
Bump-off 10
Pick-outs 10
Steel core pins 10
Text 11
Tab gate 11
Self mating parts 12
Tolerance 12
Choosing a material 13
Select colors 14
Resin additives 14
Be the hero! 15
©2010 Proto Labs. All rights reserved. 2

TABLE OF CONTENTS
What is rapid Applications of rapid
What is Rapid Injection Molding 3 injection molding? injection molding
Injection Molding 3 Rapid mold fabrication Prototypes. Refine your design
Wall thickness 4  Molds are made from aluminum with real molded parts
 Functional testing in product
Cored Geometry 4  They are 3-axis CNC milled
 Selective use of electrical
development cycle
Warp 5
discharge machining (EDM)  Test multiple materials
Sharp corners 6
Ribs 6 There are limits to complexity  Try multiple versions
Bosses 7  Rapid Injection Molding is not Bridge tooling
Draft 7 suitable for overmolding  Production parts until
Core-cavity 8 production mold is ready
 Not suitable for inserts
 Number of side actions at the parting line Low to medium volume production
Texture 8
 25 to thousands of parts
Straight pull mold 9  No internal threads
Side actions 9 Fast real injection molded plastic parts  Just-in-time parts, use your cash
Bump-off 10
 CAD to plastic as fast as 1 day
for something other than inventory
Pick-outs 10 Panic situations
Steel core pins 10  Standard delivery 10-15 business days
 Production line shutdown
Text 11
Tab gate 11  Crash development projects
Self mating parts 12 Markets that use Rapid Injection Molding
Tolerance 12  Medical ■ Consumer Products
 Automotive ■ Appliance
Select colors 14
Resin additives 14  Electronics ■ Other high volume parts
Be the hero! 15

TABLE OF CONTENTS
Up against the A core issue
What is Rapid Injection Molding 3 wall (thickness) Core out parts to eliminate thick walls.
Applications of Rapid  You get the same functionality
Injection Molding 3 The most important design requirement in a good molded part.
Wall thickness 4 for getting good molded parts —
Cored Geometry 4 maintain constant wall thickness.
Warp 5
Sharp corners 6 Sink
Ribs 6
Bosses 7
Draft 7 As designed As molded
Original geometry
Core-cavity 8
Texture 8
Warp
Side actions 9
Bump-off 10
Pick-outs 10
Steel core pins 10
Cored geometry
Text 11
Tab gate 11
Self mating parts 12 Cored geometry
Tolerance 12
* Tip: Good injection molded part design relies on a consistent * Tip: Unnecessary thickness can throw off part dimensions, reduce
Select colors 14 wall thickness to minimize the potential for warped or strength and necessitate post-process machining.
Resin additives 14 distorted parts.
Be the hero! 15

TABLE OF CONTENTS
Let’s get absolute A warped personality
What is Rapid Injection Molding 3
Recommended absolute wall Eliminate sharp transitions which
thickness by resin. cause molded-in stress.
Injection Molding 3
Recommended Wall
Wall thickness 4
Resin Thickness (inches)
Cored Geometry 4
Recommended wall thickness 5 ABS 0.045 - 0.140
Warp 5
Acetal 0.030 - 0.120
Sharp corners 6
Ribs 6 Acrylic 0.025 - 0.150
Bosses 7 Liquid crystal polymer 0.030 - 0.120
Draft 7
Long-fiber reinforced plastics 0.075 - 1.000
Core-cavity 8
Deep (milling) impact 8 Nylon 0.030 - 0.115
Texture 8 Design 3D structures that support themselves.
Polycarbonate 0.040 - 0.150
Side actions 9
Polyester 0.025 - 0.125
Bump-off 10 Polyethylene 0.030 - 0.200
Pick-outs 10
Polyphenylene sulfide 0.020 - 0.180
Steel core pins 10
Text 11 Polypropylene 0.025 - 0.150
Tab gate 11 Polystyrene 0.035 - 0.150
Note: these are general guidelines, subject to part geometry and
Tolerance 12
molded construction. Large parts shouldn’t be designed
Choosing a material 13 with the minimum wall thickness.
Select colors 14
Resin additives 14
* Tip: Protomold’s general rule for wall thickness is 0.040 - 0.140.
Be the hero! 15

TABLE OF CONTENTS
Get the stress out Give ‘em a good ribbing
What is Rapid Injection Molding 3 Sharp corners weaken parts. To prevent sink, ribs should be no more
Applications of Rapid  They cause molded-in stress from resin flow. than 60% of the wall’s thickness.
Injection Molding 3
Wall thickness 4  They form a stress riser in your application.
Cored Geometry 4
Warp 5
Sharp corners 6
Ribs 6 Bad Better
Bosses 7
Draft 7
Core-cavity 8
Texture 8
Side actions 9
Bump-off 10
Stress Riser
Pick-outs 10
Steel core pins 10 * Tip: If Protomold asks for greater wall thickness on your 40-60%
Text 11 T wall, consider increasing your T wall to compensate
Tab gate 11 for this increased thickness to reduce the risk of sink.
Tolerance 12
Select colors 14
Resin additives 14
Be the hero! 15

TABLE OF CONTENTS
Thin bosses are in Get drafted
What is Rapid Injection Molding 3  Don’t create thick sections with screw bosses. Draft (slope the vertical walls) as much as
Applications of Rapid  Thick sections can cause sink possible — this makes it easier to eject
Injection Molding 3
and voids in your part. parts without drag marks or ejector punch
Wall thickness 4
marks. You get better parts, faster.
Cored Geometry 4
Warp 5
Sharp corners 6
Ribs 6
Bosses 7
Draft 7
Core-cavity 8
Texture 8
Side actions 9
Bump-off 10
Pick-outs 10
Steel core pins 10
Text 11
Tab gate 11
Tolerance 12
Select colors 14
Resin additives 14
Be the hero! 15

TABLE OF CONTENTS
Core-cavity Deep (milling) impact
What is Rapid Injection Molding 3 When you draft, use Core-Cavity instead of Draft the part as much as possible. This allows
Applications of Rapid ribs if you can. It allows you to have constant us to make deeper features for you. Draft
Injection Molding 3
wall thickness rather than walls with a thick allows us to reduce tool chatter and cosmetic
Wall thickness 4
base. We can mill molds with better surface defects when milling deep walls. If you can fit
Cored Geometry 4
finish and deliver better parts faster. it in, use 1 degree of draft or more. On core-
Warp 5 cavity designs, try to use 2 degrees or more.
Sharp corners 6 A rough rule of thumb is 1 degree of draft for
Ribs 6 each of the first two inches of depth. From 2 to
Bosses 7
4 inches of depth, either 3 degrees of draft or a
Draft 7
minimum of 1/8” thickness may be required.
Core-cavity 8
Texture 8
Straight pull mold 9 Texture
Side actions 9 Deep Rib Approach Core-cavity Approach Protomold can add bead blast texture to the
Bump-off 10
mold for your parts. Light texture requires 3
Pick-outs 10
Steel core pins 10
degrees of draft minimum on vertical walls.
* Tip: This option is faster and less expensive to manufacture. Medium texture requires 5 degrees.
Text 11
Tab gate 11
Tolerance 12
Select colors 14
Resin additives 14
Be the hero! 15

TABLE OF CONTENTS
Straight (pull) shooter Just a side action
What is Rapid Injection Molding 3 Sliding shutoffs are your friend — these Side actions can form undercuts on the outside of
Applications of Rapid features can be made in a straight-pull mold. your part. Undercuts must be on or connected to the
Injection Molding 3
They do require 3 degrees of draft, but save parting line. They must be in the plane of the parting
Wall thickness 4
significant money over side actions. line. Protomold can do up to 8 side actions per part.
Cored Geometry 4
Warp 5
Sharp corners 6
Ribs 6
Bosses 7
Draft 7
Core-cavity 8
Texture 8
Side actions 9
Bump-off 10
Pick-outs 10
Steel core pins 10
Text 11
Tab gate 11
Tolerance 12
Select colors 14
Resin additives 14
Be the hero! 15

TABLE OF CONTENTS
Bumpoff Pick-outs
What is Rapid Injection Molding 3 A “bumpoff” is a small undercut in a part A pickout is separate piece of metal that is
Applications of Rapid design that can be safely removed from a inserted into the mold to create an undercut.
Injection Molding 3
straight-pull mold without the use of side It is ejected with the part, then removed by
Wall thickness 4
actions. Bumpoffs can be used to solve some the operator and re-inserted in the mold.
Cored Geometry 4
simple slight undercuts, but are sensitive to
geometry, material type, and orientation. * Tip: Using a pickout overcomes many shape and
Warp 5
positioning restrictions, but is more costly
Sharp corners 6
than sliding shutoffs, or using a side action.
Ribs 6
Bosses 7
Draft 7
Core-cavity 8 High-aspect-ratio
Texture 8 small diameter holes
These holes can be made with steel core pins
Side actions 9
in the mold. A steel pin is strong enough to
Bump-off 10
Pick-outs 10 * Tip: Mold can be made core-cavity, allowing room for
handle the stress of ejection and its surface is
Steel core pins 10 the part to “bump-off” after the mold opens. smooth enough to release cleanly from the part
Text 11 without draft. There shouldn’t be any cosmetic
Tab gate 11 effect on the resulting part, if there is, it will
be inside the hole where it won’t be seen.
Tolerance 12
Select colors 14
Resin additives 14
Be the hero! 15

TABLE OF CONTENTS
Watch your penmanship Open the floodgates
What is Rapid Injection Molding 3 Choose a sans serif font where the smallest Thin edges restrict flow and can break
Applications of Rapid feature is at least .020” thick. Serif fonts have during gate trimming. We need somewhere
Injection Molding 3
small tails which are often too small. Text that thick to gate into your part. There are may
Wall thickness 4
is raised above the part is better. We cannot be alternatives, please contact one of our
Cored Geometry 4
polish around it if the text is cut into your part. customer service engineers at 877.479.3680
Warp 5
 In SolidWorks, Century Gothic or customerservice @ protolabs.com.
Sharp corners 6
Ribs 6
26 point regular font and
Bosses 7 16 point bold create millable text.
Draft 7  Comic Sans MS 24 point
Core-cavity 8
also creates millable text.
Deep (milling) impact 8 Thin edge
Texture 8  For small text, a depth of .010”-.015” breaks at gate
Straight pull mold 9 often works well to reduce milling
Side actions 9 cost and improve ejection.
Bump-off 10
Pick-outs 10
Steel core pins 10
Text 11
Tab gate 11
Tolerance 12
Choosing a material 13 Milling cutter must
Select colors 14 be able to get into all
Resin additives 14 features of mold.
Be the hero! 15

TABLE OF CONTENTS Self-mating parts Be tolerant

Identical parts that flip over and  Protomold can hold about ±.003”
Applications of Rapid mate to themselves are possible and machining accuracy.
Injection Molding 3 save the cost of a second mold.
Wall thickness 4
 Shrink tolerance depends mainly on part
Cored Geometry 4
Elements include: design and resin choice. It varies from
Recommended wall thickness 5  Peg and hole 0.002” per inch for stable resins like ABS
Warp 5
 Interlocking rim and polycarbonate to 0.025” per inch
Sharp corners 6
for unstable resins like Santoprene.
Ribs 6  Hooks and latches
Bosses 7  There are techniques for getting the
Draft 7 most accuracy out of our process.
Core-cavity 8 Peg and hole/interlocking rim Please contact a Customer Service
Deep (milling) impact 8 Engineer at 877.479.3680 or
Texture 8
customerservice @ protolabs.com.
Side actions 9
Bump-off 10
Pick-outs 10
Steel core pins 10
Text 11
Hooks and latches
Tab gate 11
Tolerance 12
Select colors 14
Resin additives 14
Be the hero! 15

TABLE OF CONTENTS
It’s material
What is Rapid Injection Molding 3 When choosing a material for your part, relevant properties might include mechanical, physical, chemical resistance,
Applications of Rapid heat, electrical, flammability, or UV resistance. Resin manufacturers, compounders and independent resin search engines
Injection Molding 3
have data online. For resin links, visit www.protomold.com/DesignGuidelines_ResinInformation.aspx#links.
Wall thickness 4
Cored Geometry 4
Commodity resins — Engineering resins — Colors —
cheap, low to medium properties. more $, higher properties. Stock, Semi-Custom, Custom.
Warp 5
Sharp corners 6
Commodity resins Engineering resins
Ribs 6
Bosses 7 Polypropylene — soft, tough, ABS Nylon
Draft 7 cheap, chemical resistant,  Inexpensive  Reasonable cost
Core-cavity 8 makes good living hinges  Impact Resistant  Very strong
Deep (milling) impact 8 Polyethylene — soft, tough,  Equipment and handheld housings  Susceptible to shrink and warp
Texture 8 cheap, chemical resistant  Susceptible to sink – particularly glass-filled

Straight pull mold 9  High Density  Absorbs water — dimensional
Acetal
Side actions 9  Low Density  More expensive
& property change
Bump-off 10
Polystyrene — hard, clear, cheap,  Strong Polycarbonate
Pick-outs 10
brittle but can be toughened  Good lubricity and machinability  Moderate cost
Steel core pins 10
 Very sensitive to excess  Very tough
Text 11
wall thickness  Good dimensional accuracy
Tab gate 11
 Susceptible to chemical
Self mating parts 12 LCP
 Very expensive
stress cracking, voids
Tolerance 12
Choosing a material 13  Very strong Polyesters — PBT, PET
Select colors 14  Fills very thin parts PPS, PSU, PES, PEI
Resin additives 14  Weak knit lines Many, many others
Be the hero! 15

TABLE OF CONTENTS
Select colors
Stock colors — from the resin vendor are typically black and natural. Natural might be white, beige, amber,
or some other color. Semi-custom colors are created when colorant pellets are added to natural resins.
Injection Molding 3 For available colors, visit www.protomold.com/DesignGuidelines_ResinInformation.aspx#Colors.
Wall thickness 4 There is no added charge for our inventory colors. They are not an exact match and may create streaks or
Cored Geometry 4 swirls in parts. Custom colors match exactly to a Pantone or color chip. You work with a compounder and
Recommended wall thickness 5 provide us the resin. This process is slower and more expensive, but produces a more accurate match.
Warp 5
Sharp corners 6
Ribs
Bosses
6
7
Resin additives Long glass fibers are used like short glass fibers to strengthen
Draft 7 (Short) glass fibers are used to strengthen a composite and reduce creep, but make the resin much stronger and stiffer.
Core-cavity 8 and reduce creep, especially at higher temperatures. The downside is that they can be particularly challenging
Deep (milling) impact 8 They make the resin stronger, stiffer, and more to mold parts with thin walls and/or long resin flows.
Texture 8 brittle. They can cause warp due to the difference in Aramid (Kevlar) fibers are like glass fiber
Straight pull mold 9 cooling shrink between the resin and the fibers. only not as strong, but less abrasive.
Side actions 9
Carbon fiber is used to strengthen and/or stiffen a composite Glass beads and mica flakes are used to stiffen a
Bump-off 10
and also to aid in static dissipation. It has the same limitations composite and reduce warping and shrinkage. With
Pick-outs 10
as glass fibers. Carbon fiber can make plastic very stiff. high loading they can be challenging to inject.
Steel core pins 10
Text 11 Minerals such as talc and clay are often used as Stainless steel fibers are used to control EMI
Tab gate 11 fillers to reduce the cost or increase the hardness of (electromagnetic interference) and RFI (radio frequency
Self mating parts 12 finished parts. Since they do not shrink as much as interference) typically in housings for electronic components.
Tolerance 12 resins do when cooled, they can reduce warping. They are more conductive than Carbon fiber.
PTFE (Teflon) and molybdenum disulfide are used to UV inhibitor for outdoor applications.
Select colors 14
make parts self lubricating in bearing applications.
Resin additives 14
Static treatments make resins dissipate static.
Be the hero! 15

TABLE OF CONTENTS
Be the hero!
What is Rapid Injection Molding 3  Get real plastic injection molded parts made
Applications of Rapid for your project faster than your competitors.
Injection Molding 3
Wall thickness 4
 Shave days or weeks off the prototyping cycle.
Cored Geometry 4  Save the day in a line-down situation.
 Cut out the middle man — work with a
Warp 5
Sharp corners 6
company that has sales and manufacturing
Ribs 6 on the same campus.
Bosses 7
Draft 7
Core-cavity 8
Texture 8
Side actions 9
Bump-off 10
Pick-outs
Steel core pins
Text
10
10
11
Questions?
Tab gate
Self mating parts
11
12
Call your Account Manager or
Tolerance
Choosing a material
12
13
a Customer Service Engineer
Select colors
Resin additives
14
14
at 877.479.3680.
Be the hero! 15

Protomold is a service of Proto Labs, the world’s fastest source
for custom CNC machined and injection molded parts.
We offer interactive and highly-illustrated ProtoQuote online quotations,

backed up by a streamlined manufacturing system that can ship real
injection molded parts in as fast as the next business day.
www.protomold.com
877.479.3680
Proto Labs, Inc.

5540 Pioneer Creek Drive
Maple Plain, MN 55359
United States
Proto Labs, Ltd.

Unit A, Hortonpark Industrial Estate
Hortonwood 7, Telford
Shropshire
TF17GX
United Kingdom
Proto Labs G.K.

729 Nakano
Ebina City, Kanagawa
243-0425
Japan
Proto Labs, Inc. 5540 Pioneer Creek Drive, Maple Plain, MN 55359 877.479.3680 WWW.PROTOMOLD.COM

Protomold - Design For Mold Ability

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Print. Bind and save.

Format: Landscape Bind in presentation

Real Parts. Really Fast.

©2010 Proto Labs. All rights reserved. 2

©2010 Proto Labs. All rights reserved. 3

©2010 Proto Labs. All rights reserved. 4

©2010 Proto Labs. All rights reserved. 5

©2010 Proto Labs. All rights reserved. 6

©2010 Proto Labs. All rights reserved. 7

©2010 Proto Labs. All rights reserved. 8

©2010 Proto Labs. All rights reserved. 9

©2010 Proto Labs. All rights reserved. 10

©2010 Proto Labs. All rights reserved. 11

TABLE OF CONTENTS Self-mating parts Be tolerant

©2010 Proto Labs. All rights reserved. 12

Core-cavity 8 makes good living hinges  Impact Resistant  Very strong

Texture 8 cheap, chemical resistant  Susceptible to sink – particularly glass-filled

©2010 Proto Labs. All rights reserved. 13

©2010 Proto Labs. All rights reserved. 14

©2010 Proto Labs. All rights reserved. 15

We offer interactive and highly-illustrated ProtoQuote online quotations,

Proto Labs, Inc.

Proto Labs, Ltd.

Proto Labs G.K.

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