ENG07032 2013 Polymer Tooling Design

General Details

Full Title
Polymer Tooling Design
Transcript Title
Polymer Tooling Design
75 %
Subject Area
ENG - Engineering
MENG - Mech. and Electronic Eng.
07 - NFQ Level 7
05 - 05 Credits
Start Term
2013 - Full Academic Year 2013-14
End Term
9999 - The End of Time
Sean Dalton
Programme Membership
SG_EPLYP_J07 201300 Bachelor of Engineering in Polymer Processing SG_EPLYP_J07 201900 Bachelor of Engineering in Engineering in Polymer Processing

This module familiarises the candidates with the mechanical considerations associated with the design and usage of plastic moulds. The module will be practically based and will consist of a combination of presentations on actual solutions to mould design problems followed by a CAD based mould design project.

Learning Outcomes

On completion of this module the learner will/should be able to;


Demonstrate an understanding of the injection mould process/cycle.


Demonstrate an understanding of the main features of mould construction


Demonstrate an appreciation of the influence of part design on plastic flow


Produce a mould design using an industry standard CAD system


Work effectively in Design Teams.

Module Assessment Strategies

The subject will be assessed as follows.

  • CAD element (40%)
  • Mould design project (20%)
  • Final written exam (40%)

Indicative Syllabus


Injection mould design: Basic mould construction: core-cavity, two part moulds, multi-plate moulds, Use of core cavity inserts and local inserts for small detail.

Producing undercut detail: external slides, split moulds and collapsible cores, hydraulic vs. guide pin actuation, threaded components and unscrewing mechanisms.

Ejection systems: Ejector pins, sleeve ejector, stripper plate moulds. Hydraulic ejectors vs. tie rod actuated ejection, fixed half ejection.

Feed systems: Sprue, Runner and gate systems. Runner profiles and freeze characteristics, Gate types, size and choice of gating position. Surface vs submarine gates. Runner balancing. Hot runner / insulated runner systems.

Cooling channel design, size and layout. Heat transfer requirements.

Venting: Role of venting, choice of vent location, problems with poor venting.

Mould manufacture Manufacturing processes used in mould manufacture: Sources of mould bases and standard parts: DME, DMS, Hasco, Mold Masters etc.

The injection moulding process: Overview of injection moulding machine construction. The injection moulding cycle. Process parameters, role of melt temperature, injection and holding pressure and cooling temperature.

Part design: Design of plastic parts for mould-ability, influence of part design on plastic flow. Solving typical moulding problems, sink marks, weld lines etc.



This section will focus on the modelling of injection moulding tools for parts of varying complexity using an industry standard CAD system. Main aspect will be

  • Revision of Part, Assembly and Draft tools.
  • Automatic generation of core cavity and parting surfaces for simple moulds.
  • Manual generation of core cavity and parting surface for complex moulds.
  • Detection of shutout and creation of shutout detail.
  • Detection of undercut detail and modelling of slides.
  • Downloading mould base for part suppliers
  • Analysis of plastic flow and interpreting results.


In this element the student will design a mould required to produce a specified component. The student will sketch concepts for solutions drawing on past examples to select the best combination of mould elements necessary to mould the part in question. Detail drawings will then be produced of the finished design.

Coursework & Assessment Breakdown

Coursework & Continuous Assessment
60 %
End of Semester / Year Formal Exam
40 %

Coursework Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Continuous Assessment CAD assessment Continuous Assessment UNKNOWN 40 % OnGoing 2,4,5
2 Assignment Mould Design Project Continuous Assessment UNKNOWN 20 % OnGoing 2,3,4,5

End of Semester / Year Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Final Exam Written Exam Final Exam UNKNOWN 40 % End of Term 1,2,3

Part Time Mode Workload

Type Location Description Hours Frequency Avg Workload
Laboratory Practical Computer Laboratory CAD tuition 2 Weekly 2.00
Site Visit Not Specified Visit to moulding company 7 Once Per Semester 0.47
Independent Learning UNKNOWN Assignments 2 Weekly 2.00
Practical Flat Classroom On site practical days 8 Monthly 2.00
Total Part Time Average Weekly Learner Contact Time 4.47 Hours

Module Resources

Non ISBN Literary Resources

Injection Mould Design, RWG Pye, Longman Scientific

Injection Mold Design Engineering, David O Kasmer, Hanser


Other Resources

Solid works and Mould Design on line training material

Solid Professor (www.solidprofessor.com)

Igetit cad training (http://www.myigetit.com/)

Additional Information