MATL07006 2009 Polymer Tooling : Design and Manufacturing Techniques

General Details

Full Title
Polymer Tooling : Design and Manufacturing Techniques
Transcript Title
Polymer Tooling
N/A %
Subject Area
MATL - Materials
MENG - Mech. and Electronic Eng.
07 - NFQ Level 7
05 - 05 Credits
Start Term
2009 - Full Academic Year 2009-10
End Term
9999 - The End of Time
Donal Lyons, Stephen Reid, Michael Moffatt

This Module familiarises the candidates with the mechanical considerations associated with the design and usage of plastic moulds. Problem-solving exercises of various scope and format will be assigned, along with in-class presentations on a specialty topics.

Learning Outcomes

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


Demonstrate an understanding of the fundamental concepts of modern mould design.


Demonstrate an ability to apply knowledge of basic sciences and engineering to design and analysis of plastic moulds.


Work effectively in Design Teams


Demonstrate capability to produce mould designs with the aid of a commercial CAD package.


Communicate effectively with the engineering community and general public.

Indicative Syllabus

Injection mould design, basic principles of two part moulds, general mould construction, mould cavities and cores, methods of manufacture, use of local inserts and ancillary items. Also modern methods of prototype moulding. Availability of standard mould parts and units, DME, DMS, Hasco, Mold Masters.

Gating: Gate positioning and choice of gate. Runners: Runner profiles size and freeze flow characteristics.

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

Venting: Parting line vents, cavity venting, runner venting, moulding problems associated with inadequate venting. Ejection techniques, for side cores, undercuts etc. Designing for undercuts, threaded components, unscrewing mechanisms.

Design for 2, 3, and 4 plate moulds. Hot runner mould design and insulated runner design. Hot tip gate design. Stack moulds, 2-stack and 3-stack.

Die design, construction of principle types of die designs, cooling, effects of process and material parameters, fault diagnosis.


Computer Aided Mould Design

  • Parting Surfaces
  • Manual Parting surfaces
  • Automatic parting Surfaces
  • Sliders and Lifters
  • Multi Cavity Moulds
  • Feed System and Moulding
  • Water Line and Ejector Pins
  • Mould Analysis
  • Mould Layout and EMX

Coursework & Assessment Breakdown

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

Coursework Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Project Design of Injection/Blow Mould for a complex plasitc component such as a computer mouse or four sided curved plastic bottle Continuous Assessment UNKNOWN 40 % OnGoing 1,2,3,4,5

End of Semester / Year Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Final Exam Written Examination Final Exam UNKNOWN 60 % End of Term 1,2,3,4,5

Part Time Mode Workload

Type Location Description Hours Frequency Avg Workload
Lecture Distance Learning Suite Online lecture 1.5 Weekly 1.50
Independent Learning UNKNOWN Preparation for weekly class 1 Weekly 1.00
Independent Learning UNKNOWN Completion of weekly Continuous Assessment 2 Weekly 2.00
Independent Learning UNKNOWN Reading assignment 1.5 Weekly 1.50
Site Visit Not Specified Visit to design facility 8 Once Per Semester 0.53
Total Part Time Average Weekly Learner Contact Time 2.03 Hours

Module Resources

Non ISBN Literary Resources

Pro/Engineer Wildfire 4.0 Toogood, Rodger, Schroff, Development Corporation, 2007

Materials Selection in Mechanical Design, Ashby, M., F., Elsevier Butterworth Heinemann, 2005

Pro/Engineer Solutions and Plastic Design Ladouceur, N., et al, Onword Press, 1999

Principles of Polymer Engineering McCrum, N., G., et al, Oxford Science Publications, 2005

Other Resources

Cambridge Engineering Selector