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The Complete Part Design Handbook, For Injection Molding of Thermoplastics

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    The Complete Part Design Handbook, For Injection Molding of Thermoplastics

    بسم الله الرحمن الرحيم






    Weighing in at 7 pounds and just shy of 900 pages, The Complete Part Design Handbook, For Injection Molding of Thermoplastics, written by Mr. E. Alfredo Campo, is the most complete and comprehensive handbook on thermoplastic product design available on the market today. It is undoubtedly the new reference manual for plastic part design in the industry.Mr. Campo has masterfully compiled hundreds of pages of reference material, equations, nomenclature, design guidelines and material properties accompanied by ample detailed real world design problems and sample calculations.

    To capture this wealth of information, one would need many books, catalogs and subject matter references. Mr. Campo has painstakingly performed this task with this publication and done so with his 35 plus years of hands-on experience in the injection molding design arena.

    This all-inclusive handbook has a total of twelve chapters. Chapter 1, Plastic Materials Selection Guide is 114 pages and rightfully could stand on its own as a book in itself. Mr. Campo introduces polymeric materials and discusses 35 families of thermoplastic materials, 8 families of thermoplastic elastomers and 16 families of thermosetting materials. For each resin family, the basic chemistry, properties, processing characteristics, advantages, disadvantages and limitations are discussed along with typical applications and example end use product illustrations.

    Chapter 2, Engineering Product Design shifts the spotlight to understanding the properties of materials and structural design of thermoplastic components. Centroid, section area, moment of inertia equations and beam deflection analysis methods. Structural analysis of beams, columns, flat circular plates and torsion. Viscoelasticity is first introduced along with creep and stress relaxation phenomena.

    Transitioning to the meat of this handbook, Chapters 3 – 7 discuss structural design characteristics for thermoplastics. Chapter 3 focuses on product wall thicknesses, structural rib design, sharp corners, bosses, threads, undercuts, integral life hinges, pin hinges, encapsulation of inserts, types of metal inserts and anchorage. This chapter points out many of the fundamental “Do’s and Don’ts” of plastic part design which many product designers unfortunately learn from attending the “part design school of hard knocks.”

    Chapter 4, entitled Thermoplastic Gearing Design discusses the material property requirements for thermoplastic molded spur gears, mounting gears on metal shafts, tolerances and overall shrinkage of gears. Plastic spur and helical gearing technology design, strength, horsepower ratings, equations, tables, analysis examples and gear specification illustrations are abundantly displayed in this chapter.

    Chapter 5 is the complete guide to Plastic Journal Bearing Design. Design principles, factors affecting performance and dimensions along with clearances, molding effects, PV limits and surface finishing. Equations, tables, and analysis examples are put forward.

    Chapter 6, is the complete guide to Thermoplastic Spring Design. Locating, fixing clip, flexible hinges and torsional spring applications are reviewed. Belleville spring washers’ equations, tables and analysis examples are included.

    Chapter 7, Thermoplastic Pressure Vessel Design, discusses thin and thick walled pressure vessels’ basic principles, equations, tables, analysis examples, design guidelines, applications and pressure vessel regulations.

    Chapter 8, Thermoplastic Assembly Methods, introduces the joining of two or more components. Each assembly method provides a description, process sequence, advantages and limitations, typical applications, equipment, product joint design and its variations. Joining methods include cold heading, electro fusion fitting, hot plate welding, solvent and adhesive bonding, metal fasteners, press and snap fits, electromagnetic, vibration, spin and ultrasonic welding methods.

    Chapter 9, Thermoplastic Effects on Design discusses basic melt behavior, degradation, moisture effects, shrinkage and other critical properties. The molding process is related to its overall effects on product design dimensions and mechanical properties.

    Chapter 10, Injection Mold Design is an incredible 176 pages and thoroughly discusses everything a product designer needs to know about mold design. Types of steels, surface finishing, classification, hot and cold runner technology and design, cavitation, gating, venting, ejection, cooling, sidewall strength, designer check list and specifications for mold construction methods.

    Chapter 11, Performance Testing of Thermoplastics introduces and discusses over 45 ASTM and UL test methods, procedures and the overall significance of the test.

    As if that were not enough, Mr. Campo’s final chapter puts forward three analysis methods to estimate the cost to manufacture molded product along with the cost of capital equipment.

    Whether you are a seasoned product designer or have a limited knowledge of polymers and/or polymeric behavior, you will undoubtedly find that this publication is an invaluable and indispensable reference manual. It also offers guidelines for specifying resins, machine selection and fundamental processing parameters.

    This handbook is not only a must have for the plastic product designer but many toolmakers and processors will find this a welcome addition to their reference manuals on injection molding.



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