Part Design and Rapid Prototyping for BMC.pptVIP

Reducing the Time to Market for New BMC Applications Part Design and Rapid Prototyping for BMC Part Design Guidelines for BMCs Design Considerations for BMCs Design to optimize inherent properties of material Use structure as-opposed to mass wherever possible Keep “Line-of-draw” in mind to minimize reduce or eliminate undercuts and/or trapped steel conditions in mold Add molding draft based on line-of draw to insure minimum wall sections are maintained Wall Stock for BMCs Maintain nominal wall stock as consistently as possible. Use structure wherever possible to increase directional strength and/or combine part features Wall Stock for BMCs Wall Stock Recommendations: Minimum recommended wall stock 2mm Thicker nominal walls required for larger parts with extended flow lengths Wall stock for small parts can be as low as .5mm Dependent on part configuration and material selection Wall Stock for BMCs Parts with Varying Wall Stock Parts with significant variances in wall stock can be successfully molded in BMC. Avoid multiple thick-to-thin transitions Avoid thin-to thick gate placement Minimize or eliminate wall stock variations near dimensionally critical features Molding Draft Line-of-draw draft angle required on all vertical part surfaces Minimum recommended draft 1-degree P/S The more draft the better! Add draft where possible to small vertical walls Linear distance vs. angular draft Draft vs. tolerances + draft / - draft Draft: Angle or taper added to vertical surfaces on a part to allow for release from mold during ejection. Molding Draft No-draft Requirements Can be successfully molded on BMC Eliminates secondary machining Commonly used for bearing bores brush-box applications. Use only where necessary Minimal length-of-draw Ejector pins surfaces adjacent to feature Undercut Features in BMC Part Designs Common in today’s BMC part designs Complex shapes not a problem Multiple undercuts common Tooling technology capable Linear