Engineering Polyurethanes – RIM Part and Mold Design Guide

Engineering Polyurethanes – RIM Part and Mold Design Guide
BaySystems
TABLE OF CONTENTS
Introduction
PART DESIGN
5 The RIM Process
6 Material Descriptions
Chapter 1
MATERIAL SELECTION CRITERIA
9 Aesthetic Considerations
10 Functional Considerations
10 Economic Considerations
Chapter 2
GENERAL PART DESIGN
13 Part Stiffness
13 Wall Thickness
15 Ribbing Design and Configuration
17 Ribbing Direction
18 Draft
19 Bosses
21 Holes, Grooves and Slots
23 Inserts
23 Metal Stiffening Inserts
24 Wood Stiffening Inserts
24 Threaded Inserts
25 Undercuts
25 Snap Fits, Wire Guides and Hinges
26 Fillers
27 Warpage in Part Design
27 Creep Considerations
27 Fatigue Considerations
28 Back Molding
Chapter 3
SOLID MATERIALS
29 Wall Thickness
29 Rib Design and Configuration
30 Radii/Fillets
Chapter 4
FOAMED MATERIALS
31 Foam Rise and Flow
31 Wall Thickness
32 Rib Design and Configuration
33 Radii/Fillets
33 Bosses
34 Structural Analysis Considerations
Chapter 5
COMPOSITE MATERIALS
35 Glass Mat
36 Reinforcements
36 Radii/Fillets
37 Pads
37 Preforms
38 Finishes
Chapter 6
POSTMOLDING OPERATIONS
39 Finishing
39 Pigmentation
40 In-Mold Coatings
40 Patching
40 Postmold Painting
40 Textures
41 Decals and Silk-Screening
41 Assembly Operations
41 Screws
42 Adhesives
43 P0stfabrication
43 Nailing/Stapling/Planing
43 Recycling Polyurethanes3
TABLE OF CONTENTS
Introduction
PART DESIGN
5 The RIM Process
6 Material Descriptions
Chapter 1
MATERIAL SELECTION CRITERIA
9 Aesthetic Considerations
10 Functional Considerations
10 Economic Considerations
Chapter 2
GENERAL PART DESIGN
13 Part Stiffness
13 Wall Thickness
15 Ribbing Design and Configuration
17 Ribbing Direction
18 Draft
19 Bosses
21 Holes, Grooves and Slots
23 Inserts
23 Metal Stiffening Inserts
24 Wood Stiffening Inserts
24 Threaded Inserts
25 Undercuts
25 Snap Fits, Wire Guides and Hinges
26 Fillers
27 Warpage in Part Design
27 Creep Considerations
27 Fatigue Considerations
28 Back Molding
Chapter 3
SOLID MATERIALS
29 Wall Thickness
29 Rib Design and Configuration
30 Radii/Fillets
Chapter 4
FOAMED MATERIALS
31 Foam Rise and Flow
31 Wall Thickness
32 Rib Design and Configuration
33 Radii/Fillets
33 Bosses
34 Structural Analysis Considerations
Chapter 5
COMPOSITE MATERIALS
35 Glass Mat
36 Reinforcements
36 Radii/Fillets
37 Pads
37 Preforms
38 Finishes
Chapter 6
POSTMOLDING OPERATIONS
39 Finishing
39 Pigmentation
40 In-Mold Coatings
40 Patching
40 Postmold Painting
40 Textures
41 Decals and Silk-Screening
41 Assembly Operations
41 Screws
42 Adhesives
43 P0stfabrication
43 Nailing/Stapling/Planing
43 Recycling Polyurethanes4
TABLE OF CONTENTS
Introduction
MOLD DESIGN
Chapter 7
GENERAL MOLD DESIGN CONSIDERATIONS
47 Part Size/Clamping Pressure
48 Mold Costs
49 Shrinkage
49 Dimensional Tolerances
Chapter 8
GATE DESIGN
51 Mixing Head
52 Aftermixers
53 Edge Gating
54 Foamed Systems
54 Dam Gates
55 Solid Systems
56 Fan Gates
58 Ball Check
58 Center-Gated Direct Fill
Chapter 9
PARTING-LINE CONSIDERATIONS
62 Mold Sealing
63 Mold Venting
64 Mold Filling
Chapter 10
OTHER MOLD DESIGN CONSIDERATIONS
65 Mold Temperature Control
66 Demolding Methods
68 Movable Cores and Inserts
69 Mold Design for Slots
69 Shear Edges

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