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Blow Molding Design Guide For Engineers, By Engineers. BLOW MOLDING DESIGN GUIDE geminigroup.net/Regency BLOW MOLDING DESIGN GUIDE: INTRODUCTION How to Use This Guide If you’ve been tasked to design a hollow part for high-volume production (3,000+ parts per year), you’ve come to the right place. Blow molding allows for complex hollow parts with tight tolerances to be produced at a lower cost and with faster cycle times than other molding methods such as rotomolding. It’s no wonder so many engineers are turning to blow molding to solve their high-volume production needs. Design is the key driver of the cost and quality of blow molded parts. It has the power to give your company a competitive advantage or it can bring your project to a screeching halt. But where do you begin? You may have questions such as: • Will blow molding work for my part? • What does the blow molding process look like? • What special design considerations do I need to make? We were there once, too. That’s why we created this guide. It provides the basic guidelines for designing blow molded plastic parts – from the perspective of an experienced molder. It is not exhaustive; the amount of information available is simply too great. However, it serves as a starting point to better understand what goes into the blow mold design process. If you’re new to blow molding, start with the Understanding Blow Molding section. It outlines the benefits of blow molding, provides an overview of its applications, and illustrates the blow molding process. If you have an understanding of the blow molding process and just need to learn how to optimize your design, jump to Blow Molding Design to learn design principles for the most critical aspects of blow molding. Questions? We’ve found the most important factor for success in blow molding is partnering with our customers early in the design stage. So don’t hesitate to reach out to us if you have questions regarding what you find on the following pages or how it relates to your specific application. Our technical sales team is standing by at [email protected] and 248-435-7271. Enjoy! 1 geminigroup.net/Regency BLOW MOLDING DESIGN GUIDE: CONTENTS Contents UNDERSTANDING BLOW MOLDING Blow Molding Process 3 Advantages of Blow Molding 5 Technical Blow-Molded Products 5 BLOW MOLDING DESIGN Material Selection 6 Blow Ratio 7 Draft of Part 8 Radii / Corners 9 Ribs / Tack-Offs 9 Shrinkage 10 Insert Molding 11 Texture 11 Pinch Design 12 Secondary Operations 12 SUMMARY Blow Molding Terminology 13 Case Study 14 A Word of Advice 15 geminigroup.net/Regency 2 ubm BLOW MOLDING DESIGN GUIDE: UNDERSTANDING BLOW MOLDING Understanding Blow Molding BLOW MOLDING PROCESS Blow molding is an umbrella term for forming hollow plastic parts by inflating a molten plastic tube, or parison, until it fills a mold and forms the desired shape. Think of it like inflating a balloon inside of a water bottle. There are three main types of blow molding: Extrusion Blow Molding Stretch Blow Molding Injection Blow Molding Extrusion blow molding is the most Stretch blow molding is typically Injection blow molding is the least common type of blow molding and used to create plastic containers commonly used method and is used is used to manufacture complex with simple geometries such as jars to manufacture small containers in parts in large quantities. and bottles. small quantities. Extrusion Blow Molding STEP 1 STEP 2 STEP 3 STEP 4 Parison is extruded Blow mold seals Parison is inflated Parison cools and into mold around parison with air mold opens In extrusion blow molding, the parison is extruded vertically between the two open mold halves. The mold closes and the parison is inflated until it takes the shape of the mold cavity. 3 geminigroup.net/Regencygeminigroup.net/TPI BLOW MOLDING DESIGN GUIDE: UNDERSTANDING BLOW MOLDING Understanding Blow Molding (continued) Stretch Blow Molding STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 Parison is injection Parison is placed into Mold seals around Parison is inflated Parison cools and molded blow mold parison, parison is with air mold opens stretched downward In stretch blow molding, the parison is formed by injecting plastic around a core. When the injection mold opens, both the parison and core are transferred to the blow mold and securely clamped. The parison is then heated and stretched downward by the core. Finally, the air vents in the core open and inflate the parison into the desired shape. Injection Blow Molding STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 Parison is injection Parison is placed into Blow mold seals Parison is inflated Parison cools and molded blow mold around parison with air mold opens In injection blow molding, the parison is formed by injecting plastic around a core. When the injection mold opens, both the parison and core are transferred to the blow mold and securely clamped. Finally, the air vents in the core open and inflate the parison into the desired shape. geminigroup.net/Regencygeminigroup.net/TPI 4 BLOW MOLDING DESIGN GUIDE: UNDERSTANDING BLOW MOLDING Understanding Blow Molding (continued) Advantages of Blow Molding With an increasing focus on lightweighting and sustainability, engineers across the globe in nearly every industry have turned an eye towards blow molding. Its many benefits include… • Low cost for high volume production • High strength-to-weight ratio For mass-produced hollow parts, blow molding is Parts can be reinforced with a lightweight foam more cost-efficient than other processes such as core or internal ribs to increase structural strength rotomolding and thermoforming. and impact resistance. • Design flexibility • Insulation and acoustical properties Complex part geometries can be achieved to Hollows can be vacuumed or filled with a material adapt to unusual spaces between already existing to achieve high insulation and noise reduction components. properties. Technical Blow-Molded Products Typically, when people think “blow molding,” they think of water bottles, cosmetic containers, toys, and other consumer goods. It might come as a surprise to learn that blow molding is used to produce some highly technical products, too, including the following: Under Hood Air Ducts Fluid Containers Intake ducts, resonators, tuners, HVAC ducts DEF tanks, washer reservoirs, surge tanks Structural Components Functional Components Seating, consoles, panels, foam-filled parts Tubes, boots, sleeves, housings 5 geminigroup.net/Regencygeminigroup.net/TPI BLOW MOLDING DESIGN GUIDE: BLOW MOLDING DESIGN Blow Molding Design Blow Molding Design Now that you’ve read a high-level overview of the blow molding process, it’s time to start your design. It might seem a bit daunting at first, but you don’t have to get it right the first time around. Just take your best shot, then present your design to your supplier. Companies such as Regency Plastics, a Gemini Group company, will work with you to ensure that your design is optimized for your application and for the blow molding process. Regency will even run your design through simulation software to eliminate problem areas before any tooling is built. To accelerate the process, just follow these general guidelines and your design should be in pretty good shape once it hits your supplier’s hands. Material Selection When choosing a material for blow molding, it’s important to remember the material will be stretched. If the elastomeric properties of the material are exceeded, a hole will tear through the material resulting in a defective part. Other relevant properties are largely based on your application and might include mechanical, physical, chemical resistance, heat, electrical, flammability or UV resistance. Here are some questions you should consider: • Temperature exposure: What are the minimum and maximum temperatures the part will be exposed to? Remember, the first shot substrate must be able to withstand temperatures above the second shot’s melt point. • Bending stiffness: Does the material need to be flexible or rigid? What should the bending strength or deflection be? • Impact resistance: What level of hardness or surface toughness does each component require? Will the part need to withstand impact forces without shattering or breaking? • Tensile and compression strength: Will either component need to withstand pull-apart or compression forces? • Interfacing components and assembly: Does the part stand alone or is it part of an assembly? How will the part be joined to the interfacing parts (e.g., welding, adhesive, mechanically-joined, fasteners, etc.)? • Appearance: Does either component need to have a particular color, grain, texture and/or gloss? • UV resistance: Will the part be used in outdoor settings or otherwise exposed to UV rays? • Chemical exposure: What chemicals –– e.g., gasoline, diesel fuel, antifreeze, etc. –– might this part be exposed to that could compromise function? • Aging: What shelf life and product life is required of the part? If a material meets most requirements but falls short somewhere, an additive may be able to change its properties. For example, nylon 6/6 flows well, is good for thin-walled parts, and has excellent impact resistance, but you might have rejected it because of its average strength and lack of resistance to heat. Adding glass-fiber filler to the resin not only makes the nylon much stronger, but far more heat resistant. Glass also reduces the chance of sink in thick sections, but may lead to warp in thin areas, depending on material flow during the molding process. There are hundreds of materials and thousands of ways to adjust, blend or fine-tune them to produce the desired results. Resin manufacturers, compounders and independent resin search engines have material data online. It is highly recommended that you consult with your supplier when choosing a material.
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