Course detail
Polymer Prototypes
FSI-ZPP Acad. year: 2019/2020 Winter semester
Plastics are the most versatile material widely used in all sectors from the packaging industry, civil engineering, till automotive, aerospace and healthcare. Design of plastic parts is closely associated with production technology and knowledge in the design of plastic parts and are highly prized in practice. Students will learn about the basic chemical nature and structural properties of polymer materials, plastic injection molding technology and design principles for the design of injection molds, vacuum molding technology of plastics and vacuum casting into silicon molds.
The course has been upgraded with the support of the OPVK project. Project "The Studio of digital sculpture and new media", reg. No. CZ.1.07/2.2.00/28.0278, is co-financed by the European Social Fund and the statebudget of the Czech Republic.
Language of instruction
Czech
Number of ECTS credits
5
Supervisor
Department
Learning outcomes of the course unit
Students will learn about the properties and the suitability of the engineering polymeric materials. They will gain knowledge of injection molding technology and design principles for the design of injection molds. Students will get practical experience with the technologies of vacuum forming of plastics, and vacuum casting into silicon molds and with the posibilities of tools manufacturing for these technologies. Acquired knowledge will enable them to design products from plastic materials and effectively choose the production technology of the prototype within the design phase of product development.
Prerequisites
Knowledge and experience of design with CAD (Inventor, Catia, Rhinoceros, Creo Parametric), knowledge of design principles for castings.
Planned learning activities and teaching methods
The course is taught through lectures explaining the basic principles and theory of the discipline. Teaching is suplemented by practical laboratory work.
Assesment methods and criteria linked to learning outcomes
Graded course-unit credit is awarded on the following conditions: active participation in the seminars. Knowledge of principles of discussed technologies, including problems and limitations in their applications. Furthermore, it is necessary to prove knowledge by submitting manufactured prototype without serious deficiencies. Another evaluation criterion is written examination of theoretical knowledge, focused on essence of discussed problems, their solution and applications.
Aims
The aim of the course is to provide theoretical and practical experience in the design and manufacture of plastic parts and prototypes. Students become familiar with the technologies of serial and prototype production of plastic parts and with the design and technological limitations and design procedures that are required by different technologies.
Specification of controlled education, way of implementation and compensation for absences
Attendance at lectures is recommended; attendance at laboratory practicals is obligatory and checked by the lecturer. Compensation of missed lessons depends on the instructions of course supervisor.
The study programmes with the given course
Programme M2I-P: Mechanical Engineering, Master's
branch M-KSI: Mechanical Engineering Design, compulsory
Type of course unit
Lecture
21 hours, optionally
Teacher / Lecturer
Syllabus
1. – 3. Polymeric materials – classification, chemical nature, transition temperatures, rheology.
4. – 6. Production of polymers, its properties, behavior and degradation.
7. Excursion to FCH – Laboratory of polymeric materials processing.
8. – 11. Injection molding – design of plastic components, gating systems.
12. – 15. Injection molding – principles of plastic parts design, cooling of moulds.
16. – 19. Injection molding – mechanical systems of injection moulds, moulds venting, examples of moulds design.
20. – 21. Excursion to the Arburg company, manufacturer of injection molding machines and tools.
Laboratory exercise
26 hours, compulsory
Teacher / Lecturer
Syllabus
1. Vacuum forming of plastics, Formech laboratory machine.
2. CNC machining of mastermodels, milling with CharlyRobot 2U, robotic machining of molds.
3. Laboratory of plastic processing machines, extrusion, injection molding.
Vacuum casting of plastics into silicone molds.
4. Safety in the laboratory, control vacuum furnace MK Technology – System 1 .
5. Technological principles for the production of silicone molds, parting plane, cutted form.
6. Preparation of mastermodel, creating a frame for silicone mold.
7. Production of the first half silicone mold, gate system.
8. Production of the first half silicone mold, casting of silicon.
9. Production of the second half of the mold, casting of silicon.
10. Production of the second half of the mold, venting of the form.
11. Tempering of the mold, casting of prototype.
12. Disassembling of the mold, identification of errors, adjustment of the mold.
13. Tempering of the modified mold, casting of final part.