Engineering Training Services | Automotive Plastic Part Design

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Automotive Plastics Part Design Seminar

Open Enrolment
November 5-7, 2024
Management Education Center
Eli Broad College of Business
Michigan State University
811 West Square Lake Road
Troy, MI 48098 USA

Seminar Hours: 8:30 a.m. - 4:30 p.m. (registration first day at 8:00 a.m.)

Over 35 Years Strong
To register click HERE

Instructor

This three-day in-depth automotive seminar will provide information on material selection, design procedures, processing techniques, and the assembly methods required when designing with plastics in the automotive field.

Attendees will focus on what to expect from a polymeric material and discuss in detail how to make the design process as easy as possible and fully comply with FMVSS. In addition, this course will enable the automotive OEM and its supplier (1st, 2nd, or 3rd-tier) to have more effective communication. The OEMs will learn how to initiate their concepts on a solid, communal basis, thus allowing for cost-efficiencies and fewer second thoughts when they understand the scientific basis and the fine-tuning that comes with experience. A large number of automotive case histories will explain the step-by-step procedures for successful and robust designs.

Ideal Learner
This course is targeted at automotive designers, product managers, project managers, research engineers, material engineers, graduate, and undergraduate students, or anyone involved in the development and manufacture of automotive plastic products and systems. Attended by over 19,800 participants in over 35 years.

Its content is intended for a variety of automotive segments such as interior systems, telematics, powertrain, safety systems, chassis, exterior trim, front-end modules, crash management, electronics, and any other automotive and transportation applications which use plastic resins.

Over 1,300 slides will be used during the seminar. Case histories, including more than 15 short movies, will show you step-by-step procedures for successful and robust designs. In addition to the 1,300 color slides binder, each attendee will receive a free copy of the 474-page 10^th English edition of Designing Plastic Parts for Assembly textbook - a $179.99 value. Plan to attend and come prepared with questions to ask or experiences to share.

Seminar Outline - click on a topic to expand

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Plastics Materials and Automotive Technologies
- North American Automotive Plastics Usage by Segment
- Interiors: Infotaiment, Instrument Panel
- Exterior: Mega Front End Module
- Underhood: Upper Engine Module, Brake-by-Wire, Steer-by-Wire, Active Suspension
- Powertrain/Chassis: Hybrid, Run-Flat-Tire, Fuel Cells
Understanding and Selecting Plastic Materials
- Resins: Thermoplastics & Thermosets
- Structures: Crystalline, Amorphous & Liquid Crystal Polymers
- Inherently Conductive Polymers (ICP)
- BioPolymers: Poly Lactic Acid (PLA Polymers)
- Light Emitting Polymers
- Electro-optic Polymers
- Carbon Nanotubes
- Reinforcements: Glass Fibers, Aramid Fibers, Carbon Fibers
- Fillers: Talc, Mica, Calcium Carbonate, Wollastonite
- Additives, Effect of Additives, Physical Properties
- Elasticity, Toughness, Plasticity, Notch Sensitivities, Mechanical Properties
- Moisture Sensitivities, Processing Shrinkage and Post-Processing Shrinkages
- Thermal Expansion and Contraction, Creep, Stress Relaxation
- Automotive Thermal Characteristics
- Automotive Chemical Characteristics
Material Initial Selection & Screening
- Thermal Behavior, Automotive Chemicals
- Dimensional Tolerance & Burning
- Impact, Specific Gravity & Cost
- Engineering Properties, Snap Fits & Hiving Hinges
- Assembly Methods
Understanding Safety Factors
- What is a Safety Factor?
- Using Safety Factors in Automotive Design
- Design Safety Factors: Static, Dynamic, Time Related
- Processing Safety Factors
- Reliable Automotive Brands
- Operating Condition Safety Factors: Legal Aspects of Automotive Business
Rules for Proper Automotive Plastic Part Design
- Boss Design for Different Type of Polymers
- Boss Design Layout, Ribbing: Dimensions, Junctions
- Automotive Case History: BMW 550i & 750i Transmission Mount Bracket
- Automotive Case History: Mercedes Benz E-Class Seat Trim
- Wall Thickness, Fillets, Part Stiffness, Undercuts
- Draft Angles: Core Vs. Cavity, Texturing
Strength of Materials for Plastics
- Stresses: Tensile, Compressive, Shear, Torsion, Elongations (Strains)
- True Stress and Strain Versus Engineering Stress and Strain
- Poisson's Ratio, Modulus of Elasticity-Which One to Use, and How to Use It
Non-Linear Considerations
- Material: Linear and Non-Linear Polymer Models
- Geometry: Linear and Non-Linear Models
- Finite Element Analysis (FEA) and How to Use It
- Design Optimization Tools: BMX, ISight, TRIZ
- Theory of Solving Problems Inventively, Conclusions
Ultrasonic Welding
- Equipment, Type of Vibrations, Ultrasonic Cycle, Troubleshooting
- Design: Shear Joint, Energy Director Joint (Tongue & Groove)
- Fixture Design
- Ultrasonic Stake Designs: Flash, Hollow, Spherical, Knurl
- Ultrasonic Spot Welding, Swaging, Stud
Heat Staking
- Post Design: Round Solid, Round Hollow, Cross, Angled
Hot Plate Welding
- Process, Equipment, Joint Design
- Advantages & Disadvantages
- Joint Area Strength Capability
- Automotive Case History: Mercedes-Benz M-Class Windshield Washer Bottle
Vibration Welding
- Equipment, Process, Phases, Cross-thickness
- Joint Design
- Automotive Case History: PSA Peugeot Citroen - Diesel Engine AIM
- Welding Glass Reinforced Polymer
- Fixture Design
Laser Welding
- Equipment, Surface Heating, Through Transmission Infrared Welding, Staking
- Joint Design, Single Movement Mode, Continuous Illumination, Mask Welding
- Automotive Case History: Ignition & Trunk Keys
Electromagnetic Welding
- Equipment, Induction Coil Materials, Bonding Agent
- Joint Design
- Automotive Case History: Mitsubishi Motors - Power Steering Fluid Reservoir
Bonding
- Failure Theories: Adhesive, Cohesive
- Substrate Wettability Tests
- Drafting Symbols for Bonding
- What is Surface Energy and How to Improve It
- Surface Treatments: Corona, Plasma, Flame
- Bonding Stresses: Tensile, Compressive, Shear, Peel, Cleavage
- Joint Designs
- Automotive Case History: Chrysler CCV Vehicle
- Stress Cracking, Adhesives, Solvents
Automotive Painting
- Adhesive Promoters, Primers, Base Coat, Top Coat
- Painting Considerations, Painting Work Flow
- Power Wash Parameters
- Automotive Case History: Mercedes-Benz E-Class Wheel Hub
Press-Fits
- Material Properties, Geometric Definitions, Safety Factors, Creep, Loads
- Press-Fit Theory
- Design Algorithm Methodology
- Case History: Cassette Deck
- Solution and Discussion: Case A, B, C, and D
- Automotive Case History: Chrysler 300M - High Output 3.5l V-6 Engine
- Fusible Core Injection Molding, Upper Intake Manifold Background
- Design Requirements, CAMPUS Database
- Material Properties, Summary: Geometry/Material Properties
- Algorithm, Conclusion
- Case History: Examples of Successful Press-Fit Designs
Living Hinges
- Design for PP, PE, Common Living Hinge Design
- Design for Engineering Plastics, Living Hinge Design Analysis
- Elastic, Elastic/Plastic, Plastic Hinge Designs
- Automotive Case History: GM World-Class Electrical Connector
- Step-by-Step Design Analysis
- Automotive Case History: Delphi Ignition Cable Bracket for V-6 Engines
- Molding Hinges, Processing Issues, Coined Hinges
- Exercise 1: Design, Material Selection, Tooling & Processing
- Oil-Can Terminology & Concepts, Oil-Can Designs Incorporating Living Hinges
- Software Demo for Designing Living Hinges
Snap Fits
- Material Considerations, Design Considerations
- Assembly Positioning, Assembly Motions, Yield Criteria Safety Factors
- Cantilever Snap-Fits
- Snap-Fits: Instantaneous Moment of Inertia, Angle of Deflection, Self-Locking Angle
- Automotive Case History: One-Way Continuous Beam with Rectangular Cross Section
- Exercise 2: Cantilever Beam Calculation
- Finite Element Analysis Example
- Case History: Hewlett-Packard Omnibook
- Annular Snap-Fits: Shallow Groove, Deep Groove
- Case History: Pen & Cap
- Torsional Snap-Fits: Round, Round Hollow, Square, Triangular
- Automotive Case History: GM World Class Electrical Connector
- Deformable Rib Design, Springiness Rate, Automotive Recyclability Symbols for Plastics
- Assembly-Disassembly Assists, Over-deflection Prevention
- Tooling for Snap-Fits, Issues with Snap Fitting
- Case History: Injection Blow Molded Bottle Assembly
- Serviceability, Conclusions
- Software Demos for Snap-Fits
Automotive Integral Seal Design
- Design Issues: Integral Seal - Design A, Integral Seal - Design B
- Structural Analysis: Step 1 through 7, Material Model
- Engineering Stress-Strain Curve
- True Stress-Strain Curve - Plastic Region
- Analysis Results: Total Displacement, Von Mises Stress Detail
- Simulating Leak Through Seal 1, Simulating Leak Through Seal 2
- Processing Issues, Drying, Melt Temperature, Injection Pressure
- Injection Rate, Screw Forward Time, Mold Temperature, Cooling Time, Screw Retraction
- Tool Design: Mold Closed - Part Filling
- Mold Opening Phase 1 - Gate Breaks, Mold Opening Phase 2 - Slide Moves
- Part Ejection, Sprue & Runners, Gates: Tunnel (Submarine) Gate Features, Pinpoint Gate
- Venting
Troubleshooting
- Air Traps, Black Specks, Burn Marks, Dark stripes
- Flashing, Flow Marks, Hesitation, Jetting, Parts Not Releasing from Tool
- Peeling, Sink Marks, Shrinkage, Splay, Sprue Sticking, Unfilled Parts (Short Shots)
- Unmelt, Warpage, Weld lines
Over-molding + InMold Assembly
- Reasons for Multi-Material
- Part Design & Material Selection
- Indexing (Rotating Platen) Tool
- Mold with Core Retraction
- InMold Assembly
- Case History: FitLogic
- Automotive Case History: Louver Assembly
- Automotive Case History: Mercedes-Benz C-Class Tumble Valve Bearings
- ABS, ASA, CA, EVA, PA, PC, PE, PMMA
Tooling Considerations
- Gate Design: Direct (Sprue), Edge (Standard), Film, Fan, Tunnel (Submarine), Pin (Point), Ring, Sprue, Spoke, Disk, Tab, Diaphragm, Valve, Hot Runner
- Sprue Design: Reverse Taper Puller, Z Sprue Puller, Ring Sprue Puller, Sprue Design Formula
- Runner Design: Runner Cross-Section
- Runner Layout: Herring Bone, H-Type, Star
Processing Issues for Design Engineers
- Melt Temperature Profile, Screw Design, Boost Stage
- Fill Speed, Hold Stage, Tool Temperature & Back Pressure
- Reducing Part Weight & Size, Increasing Part Weight & Size, Venting
- Exercise 3: Design, Material Selection, Tooling and Processing
Fasteners
- Self-Threading
- Recessed Driving Heads, Tread Forming
- Clamp Load Vs. Time, Torque Vs. Penetration Depth
- Type AB (Standard Thread), Type B (Standard Thread), Type C (Standard Thread)
- Hi-Lo, PT (Plastic Thread), Free Body Diagram
- Pullout Load Vs. Engagement Area
- Assembly Stress, Plastic Boss Design for PT Fasteners
- RS Plast, Delta PT , Polyfast, and Plastite Thread Designs
- Automotive Case History: Threaded Assembly Calculation
- Weld and Meld Line Present into a Plastic Part
- Weld Lines in Parts made of Reinforced polymers
- Thread Cutting: Type BF, T, Hi-Lo, RS Duroplast, and Duro PT
- Pilot Hole Design detail
Plastic Part Design on the World Wide Web
Free review of attendees' projects
- Individual Consulting Services --- Seminars attendees can sign up for individual consulting sessions with the instructor. The sessions are free and allow the attendee to ask questions and discuss details that cannot be handled in a larger group. Consulting sessions are 20 minutes long and are handled on a first-come-first-served basis. You can sign up for a consulting session after you register for the seminar by calling 248-539-0473 or during the seminar by contacting the instructor.