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Use of plastics in the automotive industry

Plastics are generally used in automotive industry for manufacturing like bumpers and dash boards, in consumer industry to create enclosure for mobiles phone, display panel for television, mouse, and keyboard and in medical, packaging industries and safely equipment’s are the other industrial area where plastics are used extensively.

Design elements associated with plastic product development

When it comes to plastic product development, there are certain design aspects that are to be taken into consideration. Some of them are discussed below in brief:

Many times, product design specialists need to increase the stiffness of a particular component as it needs to withstand substantial load that is applied to its design. To address this matter, the best and easiest way is to add ribs and change the part geometry. Using ribs is not only practical method but it is also an economical way to increase a part’s structural strength. However, it is important to follow certain rules while adding ribs so as not to cause surface blemishes or sink marks on the parts. For instance, the thickness of the rib should always be less than the wall thickness. Additionally, it is always better to add more number of ribs for a particular stiffness instead of the height.

Bosses

Bosses are mainly used for mounting, locating and assembly purposes. One of the most important aspects to consider while placing them is the nominal wall thickness. A lot of times the bosses are made with the thick wall sections which can affect the overall look of a plastic part as well as the final product. Ideally, wall thickness around the boss design feature must be maintained at 60% of nominal part thickness in case that thickness is lower than 1/8^th of an inch.

Holes

Holes are usually made in the molded parts. The core pins that are inserted into mold cavity give rise to the holes when that part gets molded. It is easier to create through holes in molded parts than the standard blind holes.

Key points for plastic part design

During , there are many critical parameters that should be maintained, these could be the drafting angle, parting line, maintaining a uniform wall thickness and so on, so that by maintaining these parameters stress in mold, sink marks, warpage, and tolerances during the molding of the part can be avoided. A few good practices are listed below:

• To maintain uniform thickness across the radius and horizontal & vertical walls
• To provide ribs to strengthen the boss
• To create ribs for uniform flow of mold and weight reduction

Keeping the above consideration in mind during the design phase can help greatly to attain the desired benefits of using plastic. These benefits in terms of cost reduction, ease of manufacturing through injection mold for the higher quantity and superior quality and the appearance of the parts contribute to extensive adoption of plastic in the by the industry.

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During the design phase, the design engineers take utmost care to ensure longevity of the product. However, sooner or later, the task of sustaining the product is bound to arise and thus needs to be a prominent phase of the product life cycle. Several activities can be performed by the manufacturer to ensure continued Life Cycle of the product. We here are highlighting on some of the crucial parameters that the manufacturer needs to bear in mind.

Effective sustenance of a product requires proactive action. It is critical to detect potential hurdles as early as possible. A basic and essential task is a periodic Life Cycle Analysis on every part of the . This analysis needs to track availability and conformance to prevailing regulatory standards for every part of the BOM. When a change in part status or non-conformance is identified appropriate action has to be initiated. The solution can sometimes require re-design of a PCBA of the product. If the changes to implement the solution are substantial, re-certification of the product is sometimes required. In many cases a non-trivial design effort is required.  With market challenges like product substitute employing newer technologies being introduced also calls for continuous improvement in the Product. The manufacturer also needs to ensure that the features, cost and power efficiency of the product are comparable to these newer products. This is best achieved by periodically performing a Value Engineering analysis on the product.

The engineering team invariably receives several suggestions for product improvement from the sales team as well as customers. These inputs need to be analysed and addressed on regular intervals to ensure relevance of the product in the market scenario.

Sometimes the manufacturing team may face problems in the process that may reduce the yield and efficiency of the product and increase its cost, due to unpredictable conditions. Additionally there could be requirement for conformance to varying standards related to environment and reliability. These challenges have to be promptly handled by the product design team and the earliest resolutions would then contribute to better return on investments.

With the current competitive market conditions Product sustenance is gaining prominence in the PLC and to ensure better suitability of a product in regards with cost, performance and quality it is important that the design teams adopt pro-active strategies to stay ahead in the market.

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�ۿ۴�ý, a global provider of engineering design and data management services, today announces successful completion of its first project in association with Diftec. �ۿ۴�ý commenced its partnership with Diftec in the 1st quarter this year, to bring in synergies of on-site program management and customer support & off-site time and cost benefits. The partnership endeavours to deliver supreme quality product design services to esteemed clients across the Spanish market.

�ۿ۴�ý, represented by Diftec in Spain, signed the company’s first Spanish Client for development of a milk vending machine. The Client is a leader in the vending industry and has an experience of delivering innovative high quality equipment for the past 5 decades. The project comprised of designing and creating prototypes for milk froth housing and thermo block unit assembly. The project was executed by �ۿ۴�ý’s skilled team of mechanical engineers, working in Bangalore (�ۿ۴�ý’s delivery centre location) and involved a high degree of technical expertise led by experienced project managers. �ۿ۴�ý team closely aligned themselves with their Diftec counterparts to enable clear project requirement understanding and efficient delivery mechanism. The team managed to complete the project within the stipulated deadline of 6 months.

On the occasion �ۿ۴�ý’s CTO who was the focal point for the Diftec partnership said, “By completing our first project successfully for a large Spanish enterprise, we have achieved a major milestone in our pursuit to expand into the Spanish market. We are in discussion with multiple companies in Spain for offering our expert services in electronic design, mechanical design and embedded software. We are extremely enthused to provide our services and expect to initiate multiple engagements in Spain in the area of product development by the first quarter of 2015.”

About Diftec

Diftec is a solution provider for the electronics industry in Spain. The company offers extensive experience in the management of multifunctional teams in international new product development projects and in the development of embedded electronics systems.

About �ۿ۴�ý Technology Services

�ۿ۴�ý Technology Services (enventure.com) is a privately-held, ISO 9001:2008 certified engineering solutions company, with full-fledged engineering service delivery center in India. �ۿ۴�ý has been serving clients in North America and Europe since 1997 and is today a preferred supplier of engineering and data services to Fortune 500 companies, across different industry verticals such as Hi-tech electronics, Medical device manufacturers, Oil & Gas, Automotive and Heavy machinery. �ۿ۴�ý provides a wide variety of services to its clients, in areas such as Master data services, MRO data services, Component Engineering, Environmental Compliance Support, Electronic Design, PCB Design, Plant Design Engineering, Piping Engineering, Mechanical design, CAD, CAM, CAE and Technical Documentation

Media Contact:

Unni Mecheeri (��-��������:��unni.mecheeri@enventure.com)

For more info, contact:

Unni Mecheeri

E-mail: unni.mecheeri@enventure.com

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