Basics of Plastics design for design engineers from Udemy

Plastics as a family of materials have been exceedingly used for product design .

Designing with the plastic materials is generally not so straightforward as steels and aluminum. Due to the dependency of material properties on various factors.

This course is an attempt to collate the important considerations when designing with plastic materials.

Topics covered:

1. What are polymers and plastics

2. Difference between thermo plastics and Thermosets

3. Difference between amorphous and crystalline types

4. The advantages and disadvantages of using plastics for design

5. Importance of data and tests - Design approach

6. Mechanical behaviour - Stress strain diagram

7. Flexibility, rigidity, Ductile vs brittle behaviour, Linear and Non linear behaviour

8. Yield point and Elongation

9. Glass transition temperature and its importance

10. Visco elastic behaviour - Models

11. Phenomenon of Creep and how it takes place

12. Creep rupture definition

13. Behaviur in Fatigue and Fracture toughness compared to steel

14. Impact toughness and which plastics are superior compared to others?

15. Hardness property and its measurement , importance

16. Abrasion and Friction properties . Plastics which are good selection for anti friction applications

17. What are re-inforced plastics. Their impact and Anisotropy

18. Designing plastics within the larger Design process. Steps to consider, checks to include.

19. Material selection guide and factors to consider when selecting apt material

20. Dimensional stability, tolerances

21. Design for Injection molding

This course is designed to aid Design engineers in the Plastics product design activity. To go beyond CAD skills and develop holistic fundamental understanding of behaviour of plastics . Helping to make better material decisions and design decisions.

What's inside

Learning objectives

What are different types of plastics and why they are useful
Mechanical behaviour of plastics
Creep phenomona and visco elastic behaviour

Plastics in fatigue, impact and hardness property
What are reinforced plastics
Design process, parameters and factors to consider

What are different types of plastics and why they are useful
Mechanical behaviour of plastics
Creep phenomona and visco elastic behaviour
Plastics in fatigue, impact and hardness property
What are reinforced plastics
Design process, parameters and factors to consider

Syllabus

Introduction

Setting context and scope

Background about polymers

Advantages and Disadvantages of plastics in Design engineering

Design Approach

Types of Plastics - Amorphous and Crystalline

Thermo Plastics vs Thermoset plastics

Thermoplastics - Summary

Mechanical behavior of plastics

Introduction summary of Mechanical behaviour

Stress strain diagram - comparison

Flexibility, Plasticity and Non linearity

Yield point

% Elongation and Reference tensile data

Poisons ratio and shear properties

Glass Transition Temperature

Visco- Elastic behavior and Creep

Introduction to Visco-elasticity

Creep mechanism

Creep modulus

Creep rupture

Affect of Strain rate and Temperature

Behaviour in Bending and Flexural modulus

Fatigue , Impact, Hardness and Damping property

Fatigue Properties

Fracture toughness

Impact Toughness

Hardness property

Abrasion and Friction properties

Damping property - Application of Visco elasticity in Elastomers

Reinforced plastics , additives and Fillers

Reinforced plastics

Additives and Fillers

Causes of Failure

Causes of Failure in Plastics

Summary of Engineering plastics with peculiar properties

Design process

Basic Design Process

Material and process selection parameters and Analysis steps

Safety Factors

Design of a Tensile plastic link

Types of Manufacturing processes

Dimensional stability, tolerances and shrinkage

Design for Injection molding

Generic Design principles of Injection molding design

Parts of Injection Molding Die

Generic Design Rules applied , examples

Core strengthening

Gate location

Sinking and Warping Defects

Bosses and Gussets

Example

Activities

Be better prepared before your course. Deepen your understanding during and after it. Supplement your coursework and achieve mastery of the topics covered in Basics of Plastics design for design engineers with these activities:

Review Material Science Fundamentals

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Reinforce your understanding of fundamental material science concepts, which are essential for grasping the behavior of plastics.

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Review textbooks or online resources on material science.
Practice solving problems related to stress, strain, and material properties.
Summarize key concepts and definitions.

Review 'Understanding Plastics Engineering'

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Gain a broader understanding of plastics engineering principles and design considerations.

View Putting Knowledge to Work on Amazon

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Read selected chapters focusing on material properties and design.
Take notes on key concepts and examples.
Relate the book's content to the course syllabus.

Material Selection Exercises

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Practice selecting appropriate plastic materials for different design scenarios to improve decision-making skills.

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Find online resources or textbooks with material selection charts.
Work through example problems, justifying your material choices.
Compare your selections with suggested solutions.

Four other activities

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Create a Plastics Properties Comparison Chart

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Solidify your understanding of different plastic types by creating a comparison chart of their key properties.

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Research the properties of common thermoplastics and thermosets.
Create a table comparing properties like tensile strength, impact resistance, and temperature resistance.
Add notes on typical applications for each material.

Design a Plastic Enclosure

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Apply your knowledge by designing a plastic enclosure for a specific application, considering material selection and manufacturing constraints.

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Choose a product that requires a plastic enclosure.
Develop design specifications, including dimensions and environmental conditions.
Select an appropriate plastic material based on the specifications.
Create a CAD model of the enclosure.

Review 'Injection Molding Handbook'

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Deepen your understanding of injection molding design principles and best practices.

View Reinforced Plastics Handbook on Amazon

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Read chapters related to design for injection molding.
Study examples of good and bad design practices.
Take notes on key considerations for mold design and part geometry.

Prepare a Presentation on Plastic Failure Analysis

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Research and present on common causes of failure in plastic parts, enhancing your understanding of material limitations and design considerations.

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Research common failure modes in plastic parts.
Prepare slides covering causes, prevention, and analysis techniques.
Practice presenting the material clearly and concisely.

Career center

Learners who complete Basics of Plastics design for design engineers will develop knowledge and skills that may be useful to these careers:

Plastics Engineer

A plastics engineer specializes in the design, development, and manufacturing of plastic products. This course is directly beneficial, covering essential topics such as the types of plastics, their mechanical behavior, and design considerations. The course's content on creep, fatigue, impact, hardness, and reinforced plastics provides a comprehensive understanding of plastic material properties. The modules on injection molding, material selection, and design processes are crucial skills for plastics engineers. This course is a worthwhile investment.

See salaries and explore the career path for Plastics Engineer

Design Engineer

Design engineers are involved in the creation and development of new products or systems. A course focusing on the basics of plastics design is directly relevant, as plastics are used extensively in various industries. This course helps one to go beyond CAD skills, developing a fundamental understanding of the behavior of plastics. The modules on material selection, design for injection molding, and dimensional stability are especially valuable. The course considers the advantages and disadvantages of plastics in the design engineering process. Aspiring design engineers may benefit greatly from this course.

See salaries and explore the career path for Design Engineer

Materials Engineer

Materials engineers develop, process, and test materials used to create a wide range of products, from computer chips and aircraft wings to biomedical implants. A strong understanding of the properties and behavior of different materials, including plastics, is essential. This course helps one understand the different types of plastics, their mechanical behavior, and their performance under various conditions. The sections on reinforced plastics, additives, fillers, and causes of failure provides invaluable insights for materials engineers. This course provides a foundation in the field for all materials engineers.

See salaries and explore the career path for Materials Engineer

Packaging Engineer

Packaging engineers design and develop packaging solutions for a variety of products. Plastics are a common material used in packaging, so understanding their properties and behavior is beneficial. This course helps one to learn about material selection, dimensional stability, and design for manufacturing. The course advantages and disadvantages of plastics in the design engineering process.

See salaries and explore the career path for Packaging Engineer

Product Designer

As a product designer, a professional is responsible for the form and function of manufactured products. This requires a deep understanding of materials, manufacturing processes, and user needs. This course, with its focus on the properties and behavior of plastics, helps one make informed decisions about material selection and design for manufacturability. The course content, particularly the sections on design process, material and process selection parameters, dimensional stability, and design for injection molding, helps one excel in this role. The course may show a product designer how to consider the advantages and disadvantages of plastics in the design engineering process.

See salaries and explore the career path for Product Designer

Manufacturing Engineer

Manufacturing engineers are responsible for designing, implementing, and optimizing manufacturing processes. As plastics are widely used in manufacturing, understanding their properties and how they behave during processing is vital. This course, with its focus on design for injection molding, dimensional stability, and tolerances, helps one to improve manufacturing efficiency and product quality. The knowledge gained can contribute to reducing defects and optimizing the use of plastic materials in manufacturing operations. The course may show a manufacturing engineer the advantages and disadvantages of plastics in the design engineering process.

See salaries and explore the career path for Manufacturing Engineer

Process Engineer

Process engineers develop and optimize industrial processes, often in manufacturing settings. If the processes involve plastics, then this course would be useful. This course helps one learn about process selection and process parameters. Process engineers develop a more holistic understanding of the behavior of plastics. The course helps one in making better material decisions and design decisions.

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Mechanical Engineer

Mechanical engineers design, develop, and test mechanical and thermal devices, including tools, engines, machines, and other equipment. This course may provide knowledge of plastic materials and their properties, which helps one in designing components and systems that utilize plastics effectively. The content on mechanical behavior, creep phenomena, fatigue, impact, and hardness properties helps a mechanical engineer to predict the performance and reliability of plastic components under various loading conditions. This course provides a strong foundation for mechanical engineers working with materials.

See salaries and explore the career path for Mechanical Engineer

Research and Development Engineer

Research and development engineers conduct research and develop new products or improve existing ones. For those working with plastics, a deep understanding of material properties and behavior is crucial. This course helps an engineer to explore new applications of plastics, improve material performance, and optimize manufacturing processes. This course helps one with setting context and scope for background about polymers. Aspiring research and development engineers may find this course to be extremely helpful.

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Quality Control Engineer

Quality control engineers ensure that products meet certain standards of quality and performance. For those working with plastic products, understanding the properties of plastics and potential failure modes is crucial. This course may show a quality control engineer how to identify and address issues related to material selection, design, and manufacturing processes. Topics like dimensional stability, tolerances, and causes of failure are especially relevant. The course's advantage is applicable to the entire design engineering process.

See salaries and explore the career path for Quality Control Engineer

Automotive Engineer

Automotive engineers are involved in the design, development, and manufacturing of vehicles and their components. Plastics are increasingly used in the automotive industry to reduce weight, improve fuel efficiency, and enhance design flexibility. This course provides automotive engineers with the knowledge of plastic materials, their properties and behavior, and design considerations. The modules on impact toughness, fatigue, and reinforced plastics are particularly relevant. This course may allow an automotive engineer to understand the advantages and disadvantages of plastics in the design engineering process.

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Aerospace Engineer

Aerospace engineers design, develop, and test aircraft and spacecraft. Plastics and composite materials are used in aerospace applications for their lightweight and high-strength properties. This course may allow aerospace engineers to learn about reinforced plastics, fatigue behavior, and impact toughness can help them to design safer and more efficient aircraft. The course's topics of focus on lightweight and high-strength properties provides a comprehensive overview of engineering.

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Simulation Engineer

Simulation engineers use computer software to model and simulate the behavior of systems or components. This course may be useful for simulation engineers looking to simulate plastic components. This course helps one incorporate material properties. This course helps one model the mechanical behavior of plastics, creep phenomena, and fatigue. The course helps one to improve the accuracy and reliability of their simulations.

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Manufacturing Supervisor

Manufacturing supervisors oversee production processes and ensure that products are manufactured efficiently and to the required quality standards. If the manufacturing process involves plastics, this course may be useful for a manufacturing supervisor to have a better understanding of the materials being used, as well as the design and manufacturing processes involved. This course helps one with understanding material selection, design for injection molding, and dimensional stability, to troubleshoot issues and optimize production efficiency.

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Biomedical Engineer

Biomedical engineers develop medical devices, equipment, and prosthetics. Plastics play a crucial role in many biomedical applications due to their biocompatibility, sterilizability, and design flexibility. This course may not be a perfect fit, but certain areas may be useful. The course helps one gain insights into material selection, design for manufacturing, and the properties of different types of plastics. Because of its broad applicability, it can be highly useful to biomedical engineers.

See salaries and explore the career path for Biomedical Engineer

Basics of Plastics design for design engineers

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