PLAST 215 - Plastic Part and Mold Design

1. Classify plastic product design requirements, such as die draw, draft angle and typical nominal wall thickness for various plastic manufacturing processes.
   • Draw examples of the common product design requirements.
   • Explain why each of the features is required.
   • Describe how and why you would integrate the requirements into the features of a part design.
   • Describe how the requirements differ between the various manufacturing processes.
2. Differentiate the advantages and limitations of part design features, such as depressions, undercuts, projections, gussets, ribs and bosses.
   • Draw examples of common part features.
   • Explain how each feature can benefit the final part design.
   • Describe the benefits and limitations of each design feature.
3. Explain how to optimize a part and mold design to maximize part quality, part performance, recyclability and safety while minimizing overall project cost.
   • Describe how part and mold design influence part quality, performance, recyclability, safety and cost.
   • Summarize how you would choose to optimize a part and mold design to affect quality, performance, recyclability, safety positively and cost.
   • Explain several ways that inefficient part and mold design can increase the cost of a project.
4. Explain how tolerances for plastic parts are defined.
   • Defend your decision to apply specific tolerances.
   • Explain your reasoning for applying tolerances.
   • Compare different tolerances, and explain why they were applied to a part design.
5. Describe the major rapid prototype methods utilized to verify a plastic product design before designing a mold and production manufacturing.
   • Explore different rapid prototyping methods.
   • Differentiate between various rapid prototyping methods.
   • Select an appropriate rapid prototyping process for your class project.
6. Anticipate common design defects for plastic parts and molds based on geometry, material and process variations.
   • Describe common part defects.
   • Explain how you would modify your part or mold design to eliminate the defects.
7. Explain how Design Failure Mode Effect Analysis (DFMEA) is used for plastic part and mold design.
   • Explain DFMEA.
   • Interpret the output of a DFMEA.
   • Define your actions after conducting a DFMEA for your class project.
8. Summarize the value of mold filling analysis simulations for plastic part and mold designs.
   • Explain mold-filling simulation.
   • Interpret the output of the simulation.
   • Define the actions you would take on your class project after conducting a mold-filling simulation.
9. Describe the unique mold design requirements for injection, compression, thermoforming, blow molding and composite manufacturing.
   • Differentiate between mold design requirements for various manufacturing processes.
   • Explain how you will apply specific mold design requirements to your class project.
   • Define the unique characteristics of molds for each manufacturing process.
10. Describe how you would select the correct runner and gate designs for a new mold.
    • Draw examples of different gate configurations.
    • Explain how you will choose the best runner and gate configurations for your class project.
11. Explain the rationale for using different mold construction materials required for injection, compression, thermoforming, blow molding and composite manufacturing processes.
    • Differentiate between the unique requirements of a mold based on the manufacturing process for which it will be used.
    • Explain why different mold materials are used for different manufacturing processes.
    • Compare different mold materials for each major manufacturing process.
12. Evaluate processes and materials selection for environmental impact.
    • Explain how part design impacts recyclability.
    • Give examples of how to reduce the plastic content in your course project.
    • Explain how to minimize waste plastic through efficient mold design.