Plastic Product Design

SARATH BABU MADDUKURI

Index

 Over View of Plastic Product Design

 Polymer Fundamentals

 Plastic Product Design Steps

 Plastic Material Selection Process

 Plastic Product Design Guidelines

 Plastic Manufacturing Process

 Basics of Injection Mold

Product Design Environment
Product Design & Development Steps

1 End Use Requirement

a) Anticipated Structural Requirement

Loads- Stresses a material will be subjected

Rate of Loading

Duration of Loading

Impact Forces

Vibration

Foreseeable Misuse

b) Anticipated Environment

Temp Extremes

c) Assembly and Secondary Operation

d) Cost Limits

e) Regulation Standards compliances

Product Design & Development Steps

1 Establish Preliminary Design( Preliminary Concept Sketch and

Sections)

2 Select the material( Expected End Use Requirement, Material

Data Sheets)

a) Mechanical Properties used for essential component design

calculations

b) Other Relevant Properties

3 Modify Design as per the calculations results and desired

function

a) Specific property balance of selected grade

b) Processing Limitation

c) Assembly Method

d) Cost of Modification
Product Design & Development Steps

4 CAD/CAE

1 Flow Analysis

2 Stress Analysis

5 Prototype and Testing

6 End Use Testing

Polymer Fundamentals
Polymer Fundamentals
Polymer Fundamentals
 INTRODUCTION

Plastics were considered as “Replacing Materials”

Today’s world plastics are unreplacable materials on the same level as the classic
materials:
- Primarily due to special combination of properties (profiles & material combinations)
- Plastics offers solutions, that are not possible with classic materials (Electronics,
Medical care, Automotive industries etc.)
- Low weight, allows high accelerations & decelerations.
- Weather resistance (Corrosion) is better than resistance of metallic materials.
- Good Electrical Isolation properties (Housings of Electrical devices)
- Low manufacturing costs, especially with injection moulding technology.
CLASSIFICATION :

MATERIALS
Metals
(as Ores)
High-Molecular
(Makromolecular)
materails
Inorganic
e.g. Glasses

Organic

Natural
e.g. Wood
Synthetic resp.
Modified material

Thermoplastics Thermosets Elastomers

Thermoplastic Crosslinkable
elastomers (vulcanisible)
elastomers
Crosslinked:rubber
PLASTICS
Thermoplastics :

They are thread-like molecules (Linear & Branched)

They are always Deformable – Fusible – Soluble.
As degree of polymerisation (molecule length) increases strength &
toughness increases, but flowability decreases.

They are further classified as

ØAmorphous thermoplastics &
ØCrystalline (Partially crystalline) thermoplastics
Amorphous Thermoplastics:

Ø Bulky thread-like molecules, with unarranged interconnected

macromolecular structures, similar to that of staples in a cotton pad.
Ø Transparent (Exception) : Styrol – copolymers with Butatein like
ABS.
Ø Lower degree of Shrinkage & high precision can be achieved with
less cost.
Ø High elastic properties between melt &
freezing (Glass transition) temperature makes it to be
produced at low holding pressure to
avoid demoulding problems & high
internal stress.
Ø They are more sensitive against solvents &
the parts are more suspectable to stress cracking.
Examples:
Polycarbonate (PC) , Polyvinylchloride (PVC),
Acrylonitrile – Butadiene – Styrene – Copolymer (ABS), etc.
Acrylonitrile – Butadiene – Styrene – Copolymer (ABS) :

Structure : amorphous Density : 1,03 – 1,07 g/cm³ Elastic-Modulus : ~ 2400 N/mm²

Properties :
High rigidity & toughness also at low temperature to – 40º C,
High Scratch resistance, High impact resistance, High suspectability to stress cracking

Temperature limits:
Short-Term ~ 100°C, Long Term ~ 85°C

Surface Quality :
High gloss surface can be achieved.
Natural colour: opaque, non-transperant

Manufacturing related properties :

Low shrinkage & low tendency to wrap,
Good Paintability & electroplatability.

Applications :
Automotive panels - (Interior & Exterior parts), etc.
Acrylonitrile – Butadiene – Styrene – Copolymer (ABS) : Applications
Polycarbonate (PC) :

Structure : amorphous Density : 1,20 – 1,24 g/cm³ Elastic-Modulus : ~ 2200 N/mm²

Properties :
High strength & Hardness, Toughness at low temperature.
High impact resistance, High suspectability to stress cracking

Temperature limits:
Short-Term ~ 135°C, Long Term ~ 100°C

Surface Quality :
High gloss surface can be achieved.
Natural colour: Transperant

Manufacturing related properties :

Low shrinkage & low tendency to wrap,
Good Paintability & electroplatability.

Applications :
Automotive panels - (Interior & Exterior parts), Headlights, Helmets, etc.
Polycarbonate (PC) : Applications
Polyvinylchloride (PVC) :
Structure : amorphous Density : 1,38 – 1,55 g/cm³ Elastic-Modulus : ~ 3000 N/mm²

Properties :
High hardness & stiffness.
High impact resistance at low temperature till -5°C, below this brittleness increases.
High suspectability to notch failure.

Temperature limits:
Short-Term ~ 70°C, Long Term ~ 60°C

Surface Quality :
High gloss surface can be achieved.
Natural colour: Transperant till Opaque

Manufacturing related properties :

Low shrinkage
High chemical resistance

Applications :
Ducts, Ventilation Channels, tubes, etc.
Polyvinylchloride (PVC) : Applications
Crystalline Thermoplastics:

Ø Bulky thread-like slim molecules, which are alligned or with each

other.
Ø Non transparent (translucent), naturally coloured good slip properties.
Ø Higher degree of Shrinkage due to higher package of molecules.
Ø Are less compressible than amorphous during hardening & freezing
temperatures, hardly faces any demoulding problems.
Ø Due to higher shrinkage may form voids during cooling.

Examples:
Polyethylene (PE), Polypropylene
(PP), Polyamide (PA), Polyacetal
(POM) etc.
Polyethylene (PE) :
Structure : Semi crystalline Density : 0.91 – 0.96 g/cm³ Elastic-Modulus : ~ 1200
N/mm²

Properties :
High stiffness & Hardness. Good elastic properties.
Practically unbreakable, ductile till -60°C

Temperature limits:
Short-Term ~ 135°C, Long Term ~ 80°C

Surface Quality :
High gloss surface can be achieved.
Natural colour: milky white

Manufacturing related properties :

No water absorption, High Shrinkage & tendency to warpage
High chemical resistance

Applications :
HR inserts, Ducts, Channels, etc.
Polyethylene (PE) : Applications
Polypropylene (PP) :
Structure : Semi crystalline Density : 0.90 – 0.92 g/cm³ Elastic-Modulus : ~ 1450
N/mm²

Properties :
High stiffness & Hardness. Stability higher than PE.
High flexural fatigue strength. Low impact strength at low temperature.

Temperature limits:
Short-Term ~ 140°C, Long Term ~ 100°C

Surface Quality :
High gloss surface can be achieved.
Natural colour: Colourless shining through

Manufacturing related properties :

No water absorption, High Shrinkage & tendency to warpage
High chemical resistance

Applications :
Car – Coverparts (Interior & Exteriors), etc.
Polypropylene (PP) : Applications
Polyamide (PA) :
Structure : Semi crystalline Density : 1.02 – 1.15 g/cm³ Elastic-Modulus : ~ 1300 -
2800 N/mm²

Properties :
High stiffness & impact strength.
Good friction & wear resistance

Temperature limits:
Short-Term ~ 170°C, Long Term ~ 110°C

Surface Quality :
High gloss surface can be achieved.
Natural colour: Translucent white-yellow

Manufacturing related properties :

Good flow properties & chemical resistance,
Not so good shrinkage. Tendency to warpage.

Applications :
Car – (Inner, Outer), Bearings, Gear wheels, etc.
Polyamide (PA) : Applications
Thermosets :

They are closely crosslinked, that is the reason they are non – thermoplastic.
They are always Non - deformable – Infusible – Insoluble.

Examples:
Epoxy (EP), Phenol-formaldehyde (PF), etc.
Elastomeres:

They are loosely crosslinked, highly elastic & show very low plastic
deformation.
They are highly deformable –Insoluble.

Examples:
Natural Rubber (NR), Ethylen-Propylen rubber (EOM, EPDM), etc.
 Design Guidelines

REQUIREMENT (For what ?, strength, assy)

MATERIAL (Cost , Manuf Prosess,Temp conds,

SELECTION Strength, Safety)

( From customer)
PACKAGING DATA &
KINEMATICS
(Locking 6 deg. Of freedom,
DECIDING SNAP & SCREW FIXING LOCATIONS DFA )

(Die-Draw direction, Minimum

FIX TOOLING DIRECTION silder’s and aesthetic
requirement )
(Packaging data,
DECIDING STRENGTHING RIBS,LOCATIONS & GEOMETRY strength requirement)

DRAFT ANGLES,RIBS WALL THICKNESS RATIO (As per design guidelines)

 Design Guidelines

( Minimum core thickness, Slider ejection

TOOLING FEASIBILITY space, Sharp corners etc.)

DRAFT ANALYSIS A & B SURFACES

SECTIONS WITH PACKAGING THROUGH SNAP & RIBS ( Tolerance issues)

 Design Guidelines

Material Selection:
The wide variety of injection moldable thermoplastics often makes material
selection a difficult task.
Factors governing material selection
Ø Cost
Ø Functionality
Ø Assembly (Typically when bonded)
Ø Temperature
Ø Strength
Ø Government Regulations.
Ø Surface finish/aesthetic etc.
 Design Guidelines
Wall thickness/ Base thickness:

Proper wall thickness determines success or demise of

a product.
Like metals injection molded plastics also have
normal working ranges of wall thickness. This can be
taken into consideration while deciding wall thickness.
Factors to be considered while deciding wall thickness.
Ø Structural strength of the part to be designed plays
important role in deciding wall thickness.
Ø Normal working ranges of wall from chart for
particular material selected.
Ø As a thumb rule 2.5mm.
Ø Prior experience or bench mark parts can also be
referred while deciding on wall thickness.
 Design Guidelines
Wall thickness/ Base thickness:

Once nominal wall thickness is decided, following are some design rules
which should be followed.
Ø Maintain uniform wall thickness wherever possible which helps in
material flow in mold, reduces risk of sink marks, Induced stresses &
consideration of different shrinkage
Ø For non-uniform wall thickness change in thickness should not exceed
15% of nominal thickness & should transition gradually.
Ø At corner areas minimum fillet at inner side should be 50% of wall
thickness.
 Design Guidelines
Core-Cavity-Slider directions & Parting
lines :
It is always recommended first to decide upon the core-cavity direction.
Generally
core-cavity direction & parting line depends upon following parameters
Ø The shape & function of the component. Shape in turn is governed by A-
Surface, packaging/environment data.
Ø Core-cavity & slider directions should be considered such that they do not
appear on A-Surfaces, unless otherwise specified & accepted by the
customer.
 Design Guidelines
Draft Angles (On component walls):

Draft is necessary for ejection of part from the mold

& are always Tooling (Die-Draw) & Slider direction.
Recommended draft angle is minimum 1deg.
Factors governing draft angle.
Ø Surface finish – Highly polished mold requires
less draft than an unpolished mold.
Ø Surface Texture (Graining) – Draft increases with
texture depth,normally 1 deg draft for every
0.025mm depth recommended.
Ø Draw depth – To keep the draft angle to minimum
as thumb rule draft angle – draw depth charts are
followed & often design engineer should discuss
with tool maker.
 Design Guidelines
Ribs :
Ribs should be used when needed for stiffness & strength
or to assist in filling difficult areas.
For structural parts where sink marks are no concerns
-Rib base thickness can be 75%-80% of adjoining wall
thickness
For appearance parts where sink marks are
objectionable: With texture (Graining) - Rib base
thickness should not exceed 50% of adjoining wall
thickness for part. Without texture
(Graining) - Rib base thickness should not exceed 30%
of adjoining wall thickness.
Some important points to consider while rib design.
Ø Draft angle on ribs should be minimum 0.5 deg per
side
Ø Rib height should be 2.5 to 3 times of wall thickness for
effective strength. Recommended to add multiple ribs
instead of single large rib, Spacing between multiple ribs
should be at least 2 times that of rib thickness.
Ø Fillets at base of ribs should be 0.5mm Minimum.
 Design Guidelines
Bosses :

Usually designed to accept inserts, self tapping screws, drive pins etc
for use in assembling or mounting parts.
Some important points to consider while Boss design:
Ø The O.D of the boss should be ideally 2.5 times of screw diameter
for self tapping screw applications.
Ø If O.D exceeds 50% of adjoining wall thickness, thinner wall boss of
O.D 2 times or less of screw diameter can be considered with
supported by ribs.
Ø Bosses should be attached to walls with ribs. Thickness at base of
rib should not exceed 50% of adjoining wall thickness.

Ø Boss inside & outside diameters should have 0.5 deg draft per
side.
 Design Guidelines
Bosses :
 Design Guidelines
Coring :

Coring in injection molding terms to addition of steel to mold for the

purpose of removing plastic material in that area
Coring is necessary to create Pocket or, Opening in the
part or to reduce heavily walled section.
 Design Guidelines
Openings :

Openings are desired in a part to eliminate sliders, cams, pullers, etc. to

accommodate features like snaps.
As general thumb rule 5deg angle in the area of mating of core &
cavity is required.
 Design Guidelines
Assemblies :

Types of assemblies :
Ø Molded-in assembly
Ø Chemical bonding assembly
Ø Thermal welding assembly
Ø Assembly with fasteners.

Molded-in Assembly : (Snap fit, Press fit, molded in threads etc.)

This is generally the most economical method of assembly.
Assembly is fast, inexpensive & does not require any additional part or
substance. Minimizes changes of improper assembly.
Some times tooling becomes complex & expensive.
 Design Guidelines
Snap fit assembly :
 Design Guidelines
Snap fit assembly :

Y = Deflection
Q values to be referred from
Material graphs
Important points to remember :
Ø Design for given assembly force or overlap length &
material.
Ø Deflection required to assemble the part should always
be less than maximum deflection(strain) for safe design.
Ø Snaps increase possibility of sliders wherever possible
try to eliminate sliders by providing slot below snap or
moving snap to outer edge of the part, if design permits.
 Design Guidelines
Press fit assembly :
ØPress fit design is more critical in plastics (Thermoplastics as they creep (Stress or Relax).
ØGood design should minimize stress on the plastic,by considering assembly tolerance between
assembled parts & clamping force due to creep relaxation.
 Design Guidelines
Adhesive joints assembly :
ØTwo similar or dissimilar plastics can be assembled in a strong leak-tight bond by using adhesives.
ØThe choice of adhesive depends upon the application & the environment to which the part would be
subjected.
ØSome of adhesives are Polyurethanes, Epoxies, Cyanoacrylates, Silicones etc.
 Design Guidelines
Bolts –Nuts - Screws :

ØCertain precaution must be taken while designing to reduce excessive compressive

stress on the plastic.
ØLarger head screw or larger washer is preferred as that contact area increases &
stress reduces.
 Design Guidelines
Molded in threads :
ØCoarse threads are preferred due to higher strength & torque limits.
ØGenerally 0.8 – 0.9 mm relief should be provided to prevent high stress at the end of the threads.
Ø To reduce the stress concentration minimum 0.25mm radius should be applied to the threads roots.
ØExternal threads should be as far as possible located on parting lines to avoid need of unscrewing
mechanism.
ØInternal threads are usually formed by an unscrewing or collapse core.
 Design Guidelines
Self Tapping Screws :
Further classified in 2 types Thread cutting & Thread forming
ØThread cutting screw is most used on brittle plastics such as thermosets & filled (50%) thermoplastics.
They should not be reinstalled
Ø Thread forming screws is mostly used on thermoplastics. They can be reinstalled for 3 to 5 times.

General Guidelines while using self-tapping

fasteners:
1. Thread engagement length 2.5 times screw
diameter
2. Boss diameter minimum 2 times of pilot hole
diameter.
3. Cored hole should have 0.25 ° to 0.5° draft.
4. Holes should be counterbored or chamfered to a
depth of 0.5mm to aid alignment & avoid cracking
of boss.
5. Sufficient clearance to be kept between screw end
& bottom of the hole.
TOLERANCE RANGE TO BE GIVEN ON DWGS:
 HOW
SLIDERS &
LIFTERS
WORK ?
SLIDER FOR UNDERCUT :

Molded Part

Undercut
Horn Pin

Slide
SLIDER FOR UNDERCUT :
SLIDER FOR UNDERCUT :

Pulled Undercut
SLIDER FOR UNDERCUT :

Cover tool

Molded
part
Horn Pin

Locking Block

Undercut

Spring
Slide core
SLIDER FOR UNDERCUT :
SLIDER FOR UNDERCUT :
SLIDER FOR UNDERCUT :
LIFTER FOR UNDERCUT :
Lifter

Undercut

Angled pin
LIFTER FOR UNDERCUT :
LIFTER FOR UNDERCUT :
LIFTER FOR UNDERCUT : Molded
part
Lifter

Undercut

Horn pin

Lose core
LIFTER FOR UNDERCUT :
LIFTER FOR UNDERCUT :
LIFTER FOR UNDERCUT :
HYDRAULIC CYLINDER FOR UNDERCUT :
Core pin Undercut

Hydraulic Cylinder
HYDRAULIC CYLINDER FOR UNDERCUT :
HYDRAULIC CYLINDER FOR UNDERCUT :
FORCED EJECTION :
FORCED EJECTION :
FORCED EJECTION :
FORCED EJECTION :
FORCED EJECTION :
 Molded Part
MULTIPLE UNDERCUTS Slide

Hydraulic Cylinder
MULTIPLE UNDERCUTS
MULTIPLE UNDERCUTS
MULTIPLE UNDERCUTS
MULTIPLE SLIDERS: Core Pin

Locking Block

Molded part

Horn Pin

Undercut

Spring
Slide
MULTIPLE SLIDERS:
MULTIPLE SLIDERS:
REFERENCES:
 Honeywell Injection Moulding Processing Guide (2002).
 Honeywell Design Soultions (2002).
 JCI Plastics Training Manual.
 Injection Moulding Design by Pye
THANK YOU
Product Design & Development Steps

1 Design For Stiffness

Relation between load and deflection of the part is Stiffness

Determined by material and geometry of the part

Material Stress Strain Curves ( Young's Modulus)

2 Design For Strength

Max Load that can be applied to a part without resulting

into part failure

Determined by Tensile stress strain curves( Tensile Strength

etc)

3 Design for Behavior overtime

Creep : Time dependent Increasing Strain under constant

stress

Stress Relaxation: Reduction of stress under constant strain

Product Design & Development Steps

3 Design for Impact Performance

Ability of material to withstand impulsive loading

Factors: type of material, geometry, wall thickness, size of

component,

operating temp, rate of loading etc

3 Design for appearance

Sink Marks, weld lines, air traps, voids, streaks,

delamination, jetting, gate marks etc

4 Design for precision

5 Design for moldability

6 Design for Recyclability

7 Design for automation

Part Application Requirement
Material Selection Process
Material Selection Process
Design Based Material Selection
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Guidelines for Injection Molded Design
Plastic Processing
Plastic Processing
Plastic Processing-Injection Molding
Plastic Processing-Injection Molding
Plastic Processing-IMD
Plastic Processing-Injection Molding
Assembly Techniques for Plastic parts
Assembly Techniques –Snap Fits

Snap fit cantilever beam type

Snap fit cylindrical Type

Assembly Techniques –Snap Fits

Factors for calculating cantilever beam for Snap

fit
Assembly Techniques –Snap Fits

Mold Design For Snap Fits

Assembly Techniques –Spin Welding
Assembly Techniques –Ultrasonic Welding
Assembly Techniques –Hot Plate Welding
Assembly Techniques –Adhesive Bonding
Assembly Techniques –Ultrasonic Insertion
Assembly Techniques –Screw and Bosses
Assembly Techniques for Plastic parts
Injection Mold
Injection Mold
Injection Mold- Slider and Stripper Plate
Injection Mold- Stripper Plate
Injection Mold- Stripper Plate
Injection Mold-Hot Runner System
 Tooling
considerations
for
product design.

128
1. Maintain aPlastic Design
uniform Major Messages
wall section - 2.0mm is typical.
2. Utilize the appropriate radii where applicable:
3. Strive to use snap fit and thread forming screws whenever possible to
eliminate hardware, maximize design for assembly (DFA), and achieve the lowest
cost.

4. Draft is mandatory. 1.5 degrees per side, plus 1 degree per 0.001 depth of
texture.

5. Eliminate side draws (slides) and undercuts (lifters) whenever possible. Use
through wall openings.

6. Use the general tolerance box - tight tolerances drive up part and tooling cost.

7. Do not put datum on flexible walls or points in space.

 Rib to Wall Ratio
Typical Rules for Rib Thickness

Conventional Thermoplastics - 0.7T some sink mark will come

- 0.4T for part which is visible.
Structural Foam - 1.0T
 Uniform Wall Sections
It is important to use uniform walls to minimize warp age and maximize manufacturability potential.

Injection Molding : 2 to 4mm

Structural Foam : 5 mm
No thin areas less than 1.5mm
No thick areas - core for uniform sections.
Always try to core from the ejector side of part.
 Draft Angles
Draft is needed to facilitate release of part from mold.

The draft to use, unless otherwise specified, is 1.5 degrees per side.

Indicate if draft is to be added or subtracted from nominal dimension.

Show draft on part whenever possible to avoid confusion as to direction.

The "No Draft Allowed" is not to be used. Even on critical areas allow 0.5 degrees.
 Limits of Undercuts
Eliminate undercuts by alternative redesign.

A minimum of 5 degree shut-off is required for all areas around a through opening. A 7 degree angle is
even better.

See "Bad" steel conditions for steel limitations

 "Bad" Steel Conditions
Generally, "Bad" steel conditions can be avoided if all standing steel has a height to width ratio of 1:1 or
better.
Slide Core

Molded Part

Undercut
Horn Pin

Slide
Slide Core
Slide Core
Slide Core

Pulled Undercut
Slide Core

Pulled Undercut
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
　　　
Slide Core

Excessive travel
Slide Core
Slide Core
Cover tool

Molded
part
Horn Pin

Locking Block

Undercut

Spring
Slide core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Locking Block Core pin

Molded
part
Horn Pin

Undercut

Spring
Slide core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Slide Core
Accelerated
Lifter 　　　　
Lifter

Undercut

Angled pin
Accelerated Lifter
Accelerated Lifter
Accelerated Lifter
Accelerated Lifter
Accelerated Lifter
Accelerated Lifter
 Accelerated Lifter
Crash condition
Hydraulic cylinder

Core pin Undercut

Hydraulic Cylinder
Hydraulic cylinder
Hydraulic pin
Ejecting molded part
Ejecting molded part
Actuating Core pin
Ejection of undercut part
Undercut

Hydraulic Cylinder

Slide Core
Ejection of undercut part
Ejection of undercut part
Ejection of undercut part
Ejection of undercut part
Ejection of undercut part
Ejection of undercut part
Ejection of undercut part
Ejection of undercut part 　
Ejection of undercut part
Pendulum Core
Pin
Pendulum Core
Pin
Pendulum Core
Pin
Pendulum Core
Pin
Pendulum Core
Pin
Pendulum Core
Pin
Pendulum Core
Pin
Pendulum Core
Pin
Pendulum Core
Pin
Pendulum Core
Pin
Center Rib with Undercut

Undercut
Center Rib with Undercut
Center Rib with Undercut
Center Rib with Undercut
Center Rib with Undercut
Center Rib with Undercut
Center Rib with Undercut
Forced Ejection
Forced Ejection
Forced Ejection
Forced Ejection
Forced Ejection
 Multiple Undercut
Molded Part
Slide

Hydraulic Cylinder
Die Opening
Die Opening
Lifter Ejection
Part Ejection
Lifter Return
Slide Return
Die Closing
Multiple External Slides
Locking Block Core Pin

Molded part

Horn Pin

Undercut

Spring
Slide
Multiple External Slides
Multiple External Slides
Multiple External Slides
Multiple External Slides 　
Multiple External Slides
Multiple External Slides
　
Multiple External Slides 　
Multiple External Slides 　
Multiple External Slides 　
Multiple Undercuts
Multiple External Slides
Locking block Core pin

Molded part

Horn Pin

Under

Spring
Slide
Multiple External Slides
Multiple External Slides
Multiple External Slides
Multiple External Slides
Multiple External Slides
Multiple External Slides
Multiple External Slides
Multiple External Slides
Multiple External Slides
 Angled
Lifter
Lifter 　　　　　　　　 Molded
part

Undercut

Horn pin

Lose core
Angled Lifter
Ejection
Ejection
Ejection
Ejection
Die closing
Die closing
 Die
closing 　　　　　　　
 A B
Impossible lifter condition
B

A
Thanks
Injection Mold-Hot Runner System