Design
Plastics can be an alternative to metals, FRP (fiber-reinforced plastic), and wood. Plastics can be more versatile, replacing multiple parts, reducing assembly costs, eliminating painting with integral color, and reducing weight. Using plastic materials, parts can be streamlined and aerodynamic.
To begin with, all part design has to satisfy the functional requirements of the product and its final end-use environment. The part cost has to be low for the projected market size. When designing and developing parts, you must focus on defining and maximizing part function and appearance, specifying actual part requirements, evaluating process options, selecting an appropriate material, reducing manufacturing costs, and conducting prototype testing.
A variety of commercial methods are used to produce thermoplastic products. Each has its specific design requirements, as well as limitations. Usually, part design, size and shape determine the best process. Because product development differs depending upon the process, your design team must decide which process to pursue early in product development. Detailed part design information can be found in the Bayer Engineering Thermoplastics: Part and Mold Design Guide (registration required) and in the Bayer Thermoplastic Part Design Checklist.
This section explains part design parameters for the thermoforming process using Bayblend ET1000 material.
