Short Customized Course (Do it right the first time (Drift)-plastics design)

Course Overview

  • Duration: 2Days
  • Certificate of attendance will be issued to those who fulfill 80% of attendance.

This course looks at the various root-causes of failed plastic parts so that participants can learn how to detect and deal with them.

Frequently the failures originate from the parts designer due to a lack of understanding that plastics do not behave like metals. The participant will be introduced to the various facets of plastics behavior and how to take advantage of them.

Plastics have a whole different set of design considerations, especially in structural applications. Nonlinear FEA is introduced in this course because it is a key element for the successful design of plastic structural parts.

CAD files containing serious design defects (creep, fatigue, weld line breakages, etc) will almost certainly escape the scrutiny of DFM reviewers, if the reviewers of the CAD files do not ask the right questions.

Also to be mentioned is that parts can fail due to inadequate tool design, resin preparation, and processing. Repercussions include: parts cannot assemble together, warpage, voids, breakage, embrittlement, etc. which lead to loss of revenue during production down-time.

Course Objectives

  • Understand where potential design flaws exist in the CAD file of a plastic part, and remedy before the tool is cut.
  • When there is a production stoppage from failure of a plastic part, where to look for root-causing.
  • Know the pitfalls to watch out for in running a nonlinear FEA simulation for a plastic part.
  • Have confidence that his/her design will be manufactureable and perform to expectations during production, and during customer usage.

Who Should Attend?

  • R&D engineers
  • NPI engineers
  • Tool designers
  • Project Management,
  • Process Improvement Manufacturing
  • Production / Supplier Quality
  • Procurement
  • Senior Management

Key Topics

  1. Why Plastics Products Fail
  2. Introduction to Plastics Materials
  3. Physical Properties And Terminology
  4. Mechanical Properties
  5. Thermal Properties
  6. Structural Analysis
  7. Design For Moldability
  8. Design For Precision
  9. Design For Appearance
  1. What is FEA? Why use FEA?
  2. Major steps of an FEA simulation.
  3. Nonlinear behaviour of plastics requires special treatment in FEA.
  4. Other nonlinear FEA situations, required for accurate predictions.
  5. Iterative FEA vs Dead-End FEA. FEA takes too long, or does it?
  6. Analyze single parts or the assembly of parts.
  7. What boundary/load conditions to use in transposing the actual usage situation to an FEA model?
  8. Why designers used FEA but get wrong results.
  9. How to spot erroneous output results from an FEA simulation.


  • Lecture Notes
  • Video Clips
  • Discussions,
  • Case studies
  • Spot questions
  • Pre- and Post- Questionnairesm

Pre Requisite

  • Some basic knowledge in the design of plastic parts, design of injection molding tools, injection molding process.

Looking For The Course Price

Contact Personnel:

Mr. Ravdarn Raman