1.

SECTION STUDY
1.Section of component along with its environment.
2.Uniform or variable thickness of component.

ENVIROMENT SECTION

PART SECTION
 2.TECHNICAL GAP AND FLUSH
CONSIDERATION
1.Through section study, Gap between part to part are considered.
2.Generally,
Plastic to plastic:3 mm
Plastic to Sheetmetal:5 mm

GAP BETWEEN
TWO ELEMENTS

ENVIROMENT

COMPONENT
 3.MAIN TOOLING CONSIDERATION
1.Consideration of Tooling depends on the way in which component is going to
eject.

2.It should be permissible that without rupturing or war page, the component
should formed.

CORE

PARTING LINE

CAVITY
MAIN TOOLING
DIRECTION
 4.PARTING LINE CONSIDERATIONS

1.It can be defined as line separating the component as core and cavity
side.

2.It assures that whatever you are designing is working in molding.

3.Generally make Core surface completely close which will be used as

parting surface itself.

4.It means you do not have to make any additional work to create Parting
surface.

5.For visible components most of the time in visible area parting line is
already defined in style e.g. glove box door, door carrier, driver side trim.
5.ASSEMBLY STUDY
According to input, the number of part sections are provided, through
which it can understood the location of particular component in an
assembly.

6.FUNCTIONS AND MATERIAL

CONSIDERATIONS

1.It is important considerations for the material used for a part to manufactured.

2.Generally ABS,PP,PVC,PBT,PC.

3.Table shows used of plastic material according to there used:

 7.A-SURFACE CONSIDERATIONS
1.A Surface design depending on Surface texturing and graining.

2.Part be design as per aesthetic purpose

8.DRAFT ANALYSIS
Draft analysis of surface is done for easily ejection of component.
It is ordered as:
Green- clear in mould
Red - zero angle
Blue - undercut
9.THICKNESS VARIATION/BOX EFFECT
1.Plastic components always design at uniform thickness, such that
mould should be properly flow to form component with great aesthetic
look.

2.In some cases, in order to avoid plastic defects at corner area,

material are reduced at larger walls. This effect is known as Box Effect.

3.Examples are Door panel ,Map pocket, Console parts etc.

10.C-SURFACE CREATION
1.It is closing condition of two surfaces.
2.It depends on environment.
It may surface to surface contact.
It may surface to surface gap.
3.In rare cases, If environment is hire, then always design C-surface in
90 deg. to mould direction line.
9.THICKNESS VARIATION/BOX EFFECT
1.Plastic components always design at uniform thickness, such that
mould should be properly flow to form component with great aesthetic
look.

2.In some cases, in order to avoid plastic defects at corner area,

material are reduced at larger walls. This effect is known as Box Effect.

3.Examples are Door panel ,Map pocket, Console parts etc.

10.JOINING TOLERANCE
1.Joining tolerance of component as per customer requirement.

2.It is kept at 0.001mm (by default).

11.CONSIDERATION OF RPS POINTS
RPS must be defined in order to have mechanical stability of the Part
in the car interface.

Ideally the RPS is composed of 6 points

 3 points that define a Plane
 2 points that define a line
 1 point to refer the system

1.RPS should satisfy the 3-2-1 principle means

2.Should restrict the 6 degrees of freedom.
12. Fixation Study (from BIW to plastic or vice-
versa
1.In order to locate the component in assembly, features
plays vital for fixing of part.

2.The features are locators, Clip tower, Doghouses, Ribs,

Snaps, Welding cylinders, Welding bosses etc.

3.The plastic components features are located using

metallic clips, screws etc.
13.FEATURE CONSIDERATIONS:-
The features such as:
Clip tower:
13.FEATURE CONSIDERATIONS:-

WELDING CYLINDER:-
Outer dia:Ø6 Welding cylinder
Inner dia:Ø4 or Ø3

Environment 1

Wall thickness reduction

to avoid sink mark:
Environment 2
DOG HOUSE
14.SLIDERS AND LIFTERS
1.For removing undercuts in plastic parts, slider and lifters are used .
For external undercuts : slider
For internal undercuts :lifter

2.Sliders are always put at 90 deg. to main tool direction, in rare cases
it may be lifted upto 15 deg.

15. CLASH STUDY

1.It should kept in mind after design of component, should be check for
analysis with environment elements, which will reduced losses in future.

2.It can minimize by performing:

1.Clash analysis
2.Sectioning
3.Distance and Band analysis.
16.PART NAMING/HISTORY
Part naming as well as tree structure should thoroughly maintained to
avoid future problems in modifications.
CALCULATION OF LIFTER DIRECTION

Tan α = Undercut
Stroke Length

X = Undercut
Stroke Length (Normally) = 150 mm

α = Lifter angle
So,

Tan α = X
150 mm
CALCULATION OF LIFTER DIRECTION

β = α+ 2 to reduce the friction between

Lifter and Main tool.

X+5 = Lifter Travel

LIFTER

Y (Total Lifter Movement) = Lifter Block + (X+5)