Protomold: Rapid Injection Molding
April Design Tip

When you really need to dodge the draft

We've spent so much time reminding designers that parts must be drafted to facilitate ejection from molds that it seems strange to talk about how to avoid having to draft parts, but it can sometimes be done when absolutely necessary. Keep in mind, however, that drafting is still the key to simplicity of design, ease of molding, and cost control. As we've said in previous Design Tips, when a surface is parallel to the direction of mold opening, it should be slightly tapered toward the mold; otherwise the mold surface will drag across the surface as the mold opens, damaging the surface. Drafting causes the part face to move away from the mold face as the part is ejected, preventing damage. The slight change in face angle usually makes no difference in either the functionality or appearance of the part. But what if it does?

Probably the most common reason not to draft a surface is to make it fit with other parts of a finished product. Figure 1 is a bracket which bolts to a machine. If the mating face is drafted, the top face tilts at an angle that is unacceptable for this application

Fig. 1

Fig. 1

For a specific requirement, like this one, Protomold can incorporate cam-driven side actions into a mold. These are typically used to create undercuts that could not be molded in a simple two-part mold. But, because cams move perpendicular to the direction of primary mold opening they can also be used to produce surfaces that are undrafted in relation to the A- and B-side mold halves.

Imagine a part with a surface parallel to the direction of mold opening. Let's assume that we cannot draft the problem surface and must find some other way to protect it during ejection (see figure 1). Protomold would normally require draft on this face as shown in figure 2.

Fig. 2

Fig. 2

If the surface cannot be drafted, so as to move away from the mold as the part is ejected, an alternate solution is to have the mold move away from the surface. This is achieved using a side-action cam (pink face in figure 3).

Fig. 3

Fig. 3

In essence, a side action works like the moving wall in the Death Star trash compactor in Star Wars. As the A- and B-side mold halves open or close along the X-axis, the cam (or cams) move along the Y/Z axes. During ejection, the cam will withdraw leaving no mold wall next to the problem face to cause problems as the part is ejected.

Aside from undrafted faces and the obvious undercut features, there are several other applications for side actions. Raised lettering on a face parallel to the direction of mold opening presents a problem even if the face is drafted; side actions solve that problem (pink face in figure 4).

Fig. 4

Fig. 4

Similarly, texture on a low-draft face, which might not be reproducible in a straight-pull mold, can be produced in a mold with side actions.

There is additional cost for each side action, and there may be some flash between the side action face and the rest of the mold. Therefore they should be considered an option with tradeoffs, not a panacea for all undercuts or zero-draft faces.

One more application is the production of decal recesses. These are shallow undercuts, but they can simplify the placement of decals and, if they fall in faces that are parallel to mold opening, are made possible using side actions. ProtoQuote® now points out areas that can be produced using side actions, giving users the option of redesigning their parts for standard straight-pull molds or using this more advanced capability.

 

ProtoQuote®

ProtoQuote

The ProtoQuote is new and improved! Try it out today:

Upload your 3D CAD model and we will email to you an informative ProtoQuote.

ProtoQuote Demo:

Still haven't tried the new ProtoQuote 3D Viewer in ProtoQuotes? Give it a try today:

Click here for the demo.

Design Guidelines

As always, you can visit the Protomold Design Guide for helpful Rapid Injection Molding design information.

Protomold Europe

Protomold Europe

European colleagues? Tell them about Protomold Europe!

Plastics Trivia Question

About the size of grains of sand, plastic "Datadots" can be:

A. applied to route shipped packages.

B. sprayed on parts to help identify stolen vehicles.

C. inserted under the skin to help recover lost pets.

D. injected to aid in medical diagnoses.

E. added to commercial explosives to identify the source.

(Honor System: No Googling, Yahooing, or Dogpiling until after you've submitted your guess.)

Last month's question/results:

The Rinspeed eXasis concept car makes unique use of plastic:

A. in its 40 percent plastic 3-cylinder engine.

B. in its transparent plastic body.

C. in its custom-contoured plastic seating.

D. to achieve its 580 kg empty weight.

E. in components of its interactive 4-wheel drive.

The correct answer is
B. in its transparent plastic body, and there are pictures available at www.rinspeed.com.

The responses are represented in the following chart:

Last Month's Results

Upcoming Tradeshows

Want to talk in person? Stop by to discuss your design.

Atlantic Design &
Manufacturing Show

June 12-14, 2007
Jakob Javits Convention Center
New York, NY

Booth #201

National Manufacturing Week
September 25-27, 2007
Donald E. Stephens
Convention Center
Rosemont, IL
Booth #4130

For more information, visit our Web site at Protomold.com.

Get a ProtoQuote

Suggestions

Please e-mail suggested topics for future Design Tips, questions for future Designer Surveys, and obscure bits of Plastics Trivia to marketing@protomold.com.