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GE Plastics Design Guide Intro.Qxd 6/16/99 10:58 AM Page 3 27947 Design Guide Cover.qxd 6/16/99 10:28 AM Page 1 GE Plastics GE Engineering Thermoplastics DESIGN GUIDE GE Engineering Thermoplastics Thermoplastics Engineering GE Guide DESIGN GUIDE GE Plastics We bring good things to life. General Electric Company One Plastics Avenue Pittsfield, MA 01201 Design 800.845.0600 PBG-130 (6/99) CA http: / / www.geplastics.com Intro.qxd 6/16/99 10:58 AM Page 2 Introduction About GE The General Electric Company has its roots in the ‘age of invention’ when, more that 100 years ago, it was founded by pioneering inventor Thomas Edison. Closely following its founder’s philosophy of innovation and the creative application of technology, GE has grown to become one of the world’s largest and most diversified companies in the world. Today, GE products and services make a positive contribution to virtually every sector of commerce and industry. From jet engines to financial services, from lighting and medical systems to factory automation, power generation, transportation and construction. About GE Plastics Of all GE businesses, one of the fastest growing is GE Plastics. In a short 25 years, GE Plastics has emerged as the leading producer of engineering thermoplastics. Through Application Development Centers around the world, customers can access assistance from GE designers, engineers, tooling, processing and finishing experts, utilizing the most sophisticated equipment and systems available. Working closely with customers on a “share to gain” basis is at the core of the GE Plastics’ business culture. It provides the technologies, ideas and improvements that will get the job done better, more cost-effectively and within tighter schedules. Having a concentration of molding equipment, testing labora- tories and product specialists close to the action enables easy access to unmatched expertise and permits a cross flow of information that leads to important breakthroughs and exciting new product developments. i • GE Plastics Design Guide Intro.qxd 6/16/99 10:58 AM Page 3 At the nucleus of this unmatched global technical network are the world-class facilities at GE Plastics’ headquarters in Pittsfield, Massachusetts. Realizing that speed is the key to profitability today, these support services are backed-up by production plants in several locations in the U.S., Europe, Australia, Japan and Mexico. The ultimate value of materials technology is its practical appli- cation in the marketplace. That is why GE Plastics offers its engineering thermoplastic resources and technologies to help design engineers and processors develop better products. There are no barriers or boundaries, No limit to the resources that can be brought together for your benefit. Engineering Thermoplastics The advantages of high performance engineering thermoplastics have grown dramatically both from new material developments and through a new generation of design engineers. Today, designers have learned to “think” in plastics and take full advantage of their inherent benefits, rather than just simply translate metal components into plastic. Some of the unique design benefits offered by GE Plastics discussed in this Design Guide include: • Consolidation of parts • Integrated system assembly • Molded-in assembly features • Unprecedented strength to weight ratios • Elimination of painting and other operations • Outstanding impact resistance • Excellent chemical resistance Through re-thinking and re-design, traditional metal assemblies can be produced in dimensionally stable plastics: with 50% fewer parts, engineered for automated assembly and offering a full range of impact, heat, electrical and chemical properties. This Design Guide is one example of how designers can benefit from the knowledge and experience available from GE Plastics. GE Plastics Design Guide • ii Intro.qxd 6/16/99 10:58 AM Page 4 Contents Introduction . .i – iii Product Development . .1-1 – 1-51 Thermoplastic Material Properties . .2-1 – 2-63 Part Performance . .3-1 – 3-46 Product Design . .4-1 – 4-35 Product Assembly . .5-1 – 5-83 Industry Specific Design Considerations . .6-1 – 6-32 Guidelines for Injection Molded Design . .7-1 – 7-15 Prototyping and Testing . .8-1 – 8-9 Quality Control . .9-1 – 9-15 Glossary . .10-1 – 10-16 Index . .10-17 – 10-21 DISCLAIMER: THE MATERIALS AND PRODUCTS OF THE BUSINESSES MAKING UP THE GE PLASTICS UNIT OF GENERAL ELECTRIC COMPANY, ITS SUBSIDIARIES AND AFFILIATES (”GEP“), ARE SOLD SUBJECT TO GEP‘S STANDARD CONDITIONS OF SALE, WHICH ARE INCLUDED IN THE APPLICABLE DISTRIBUTOR OR OTHER SALES AGREEMENT, PRINTED ON THE BACK OF ORDER ACKNOWLEDGMENTS AND INVOICES, AND AVAILABLE UPON REQUEST. ALTHOUGH ANY INFORMATION, RECOMMENDATIONS, OR ADVICE CONTAINED HEREIN IS GIVEN IN GOOD FAITH, GEP MAKES NO WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, (I) THAT THE RESULTS DESCRIBED HEREIN WILL BE OBTAINED UNDER END-USE CONDITIONS, OR (II) AS TO THE EFFECTIVENESS OR SAFETY OF ANY DESIGN INCORPORATING GEP MATERIALS, PRODUCTS, RECOMMENDATIONS OR ADVICE. EXCEPT AS PROVIDED IN GEP‘S STANDARD CONDITIONS OF SALE, GEP AND ITS REPRESENTATIVES SHALL IN NO EVENT BE RESPONSIBLE FOR ANY LOSS RESULTING FROM ANY USE OF ITS MATERIALS OR PRODUCTS DESCRIBED HEREIN. Each user bears full responsibility for making its own determination as to the suitability of GEP‘s materials, products, recommendations, or advice for its own particular use. Each user must identify and perform all tests and analyses necessary to assure that its finished parts incorporating GEP materials or products will be safe and suitable for use under end-use conditions. Nothing in this or any other document, nor any oral recommendation or advice, shall be deemed to alter, vary, supersede, or waive any provision of GEP's Standard Conditions of Sale or this Disclaimer, unless any such modification is specifically agreed to in a writing signed by GEP. No statement contained herein concerning a possible or suggested use of any material, product or design is intended, or should be construed, to grant any license under any patent or other intellectual property right of General Electric Company or any of its subsidiaries or affiliates covering such use or design, or as a recommendation for the use of such material, product or design in the infringement of any patent or other intellectual property right. iii • GE Plastics Design Guide Development Sec 1.qxd 6/16/99 10:17 AM Page 1 GE Plastics GE Engineering Thermoplastics DESIGN GUIDE Product Development Development Sec 1.qxd 6/16/99 10:17 AM Page 2 Product Development Early in design development, parts are identified as potential plastic applications and applicable manufacturing processes are considered. Designers must decide which should come first: selection of a material or a process for manufacturing a part? Normally, the configuration requirements of the plastic part will direct the design toward a process. In most cases, the process must be determined before a specific resin grade can be selected. During this review, designers also need to consider if the process is capable of meeting the design requirements such as size, shape, detail and tolerances. 1-2 • Product Development Development Sec 1.qxd 6/16/99 10:17 AM Page 3 Contents The Design Development Process . .1-4 Processing Considerations . .1-36 New Product Development . .1-4 Plastic Manufacturing Process . .1-36 The Plastics Development Cycle . .1-4 Volume Considerations . .1-38 Basic Design Guidelines . .1-6 Application Matrix . .1-42 Application Requirements . .1-8 Identifying Special Needs . .1-13 Successful Applications . .1-42 Polymer Fundamentals . .1-20 Material Selection . .1-48 Product Line Creation . .1-21 Design-Based Material Selection . .1-48 Product Line Structure . .1-21 Polymer Technologies . .1-23 Resin Families . .1-23 Product Offerings . .1-25 Resin Designations . .1-25 Computer-Based Information Resources . .1-32 Design Assistance . .1-32 Materials Selection Database . .1-33 Product Development • 1-3 Development Sec 1.qxd 6/16/99 10:17 AM Page 4 Product Development The Design Development Process New Product Development New products are frequently vital parts of a business strategy. Bringing the right product to the market at the right time and at the right price is an enviable goal. Knowing the process for new product development and executing the steps flawlessly can provide a substantial edge. Manufacturing with engineering thermoplastics continues to enable new product developers to propose innovative solutions. The Plastics Development Cycle While the development process is open to variations, offering a systematic approach can be valuable by highlighting key ele- Design Development Process ments of the process. By-passing steps or ignoring issues raised can increase the risk facing the project. Figure 1-1 presents an Three “D’s” overview of the natural progression and groupings at the three • Discover phases of the design development process, which includes: • Develop • Deliver Discover: Identify an opportunity for a product, consider the market and visualize a competitive edge you feel is obtainable. Develop: Embracing the conceptual strategy to achieve the stated product goals/requirements, create parts, assemblies and components needed to make the product. Support proposal with engineering analysis or tests. Deliver: With confidence the design will function and can be produced at acceptable cost, the manufacturing capability is ordered, supplies selected, tooling and facilities identified or built. After checking initial parts, pilots are assembled, debugged, and procedures
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