DFM and DFA Design Guidelines.PPT

Ken Youssefi UC Berkeley * DFM Design Guidelines – Machining Ken Youssefi UC Berkeley * Ken Youssefi UC Berkeley * Ken Youssefi UC Berkeley * Ken Youssefi UC Berkeley * Ken Youssefi UC Berkeley * Ken Youssefi UC Berkeley * Ken Youssefi UC Berkeley * Ken Youssefi UC Berkeley * Ken Youssefi UC Berkeley * Ken Youssefi UC Berkeley * Ken Youssefi UC Berkeley * DFM Design GuidelinesInjection Molding Injection Molding Fabrication of Plastics Ken Youssefi UC Berkeley * DFM Design GuidelinesInjection Molding Minimize section thickness, cooling time is proportional to the square of the thickness, reduce cost by reducing the cooling time. Provide adequate draft angle for easier mold removal. Ken Youssefi UC Berkeley * DFM Design GuidelinesInjection Molding Avoid sharp corners, they produce high stress and obstruct material flow. Keep rib thickness less than 60% of the part thickness in order to prevent voids and sinks. Ken Youssefi UC Berkeley * DFM Design GuidelinesInjection Molding Provide smooth transition, avoid changes in thickness when possible. Keep section thickness uniform around bosses. Ken Youssefi UC Berkeley * DFM Design GuidelinesInjection Molding Use standard general tolerances, do not tolerance; Dimension Tolerance Dimension Tolerance 0 ≤ d ≤ 25 ± 0.5 mm 0 ≤ d ≤ 1.0 ± 0.02 inch 25 ≤ d ≤ 125 ± 0.8 mm 1 ≤ d ≤ 5.0 ± 0.03 inch 125 ≤ d ≤ 300 ± 1.0 mm 5 ≤ d ≤ 12.0 ± 0.04 inch 300 ± 1.5 mm 12.0 ± 0.05 inch Standard thickness variation. Minimum thickness recommended; .025 inch or .65 mm, up to .125 for large parts. Round interior and exterior corners to .01-.015 in radius (min.), prevents an edge from chipping. Ken Youssefi UC Berkeley * DFM Design GuidelinesRotational Molding A predetermined amount of plastic, powder or liquid form, is deposited in one half of a mold. The mold is closed. The mold is rotated biaxially inside an oven. The plastics melts and forms a coating over the inside surf