International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 07 | Jul 2025
p-ISSN: 2395-0072
www.irjet.net
Design for Manufacturing: Bottle Trap Transparent Body Selvamani B, Steven Joji, Vignesh Kumar G, Dr. V. Muthukumaran 1Selvamani B, KCT, CBE. 2Steven Joji, KCT, CBE.
3Vignesh Kumar G, KCT, CBE.
4Dr. V. Muthukumaran, KCT, CBE.
---------------------------------------------------------------------***--------------------------------------------------------------------relatively low unit costs when scaled to high production Abstract - This project focuses on the optimization of the volumes.
injection molding process to manufacture a transparent bottle trap body, carried out as an industrial collaboration with Geneses Engineering. The transparent bottle trap, used beneath sinks in plumbing systems, necessitates high optical clarity and dimensional precision. However, manufacturing defects such as flow lines, flashes, and improper locking mechanisms compromise product quality. The goal of this project was to mitigate these issues through the redesign of mold features and refinement of processing parameters. Key process parameters such as melt temperature (optimized in the range of 200°C–280°C), cooling uniformity, and air vent dimensions (refined to 0.025 mm) were studied in detail.
Despite its significant advantages, injection molding is a highly sensitive process where even minor deviations in mold design, material selection, or processing parameters can dramatically affect product quality and manufacturing efficiency. Optimizing these factors is critical to minimizing defects, ensuring part reliability, and maintaining competitive production economics.
Importance of Mold Design in Injection Molding One of the most critical contributors to successful injection molding lies in the design and engineering of the mold tool itself. Within mold design, two systems are particularly crucial: the venting system and the cooling system. Both systems work hand-in-hand to regulate the behavior of molten polymer inside the cavity and to ensure that parts are formed correctly without defects.
A series of trial runs were conducted before and after optimization, and performance data such as rejection rates and product clarity were analyzed. Using Siemens NX software for redesign, and input from experienced engineers at Geneses, the project resulted in a notable enhancement in part quality and process efficiency.
Venting System: Proper venting is essential for allowing trapped air and gases to escape from the mold cavity during the injection phase. Failure to provide adequate venting can result in several quality issues, such as: Burn marks caused by compressed trapped air igniting under high temperature Short shots (incomplete filling) where air pockets prevent proper flow Weld lines and surface blemishes reducing the part’s mechanical strength and appearance Cooling System: After filling, the molten plastic must solidify uniformly. Poor cooling system design can create non-uniform temperature gradients inside the mold, leading to: Warpage and distortion of parts after ejection Dimensional inaccuracies compromising assembly fitment Increased cycle times that lower production efficiency and increase cost Thus, any shortcomings in venting or cooling directly affect product quality, production yield, and long-term tool life.
Additionally, the project considered environmental impacts, such as waste and emissions from plastic processing, promoting sustainability. This report presents the methodology, analysis, and findings of this industrial designfor-manufacturing project.
Key Words:
Injection molding, transparent plastic components, bottle trap design, venting system optimization, cooling channel design, warpage reduction, conformal cooling, design for manufacturing (DFM), Moldflow simulation, plastic part defects, mold design improvement, air trap elimination, dimensional accuracy, smart molding technologies.
1.INTRODUCTION Injection molding stands as one of the most dominant and versatile manufacturing techniques employed for massproducing plastic components across a wide range of industries, including automotive, packaging, medical devices, consumer electronics, and household products. This popularity stems from its unparalleled ability to produce complex geometries with high dimensional accuracy, excellent surface finish, and consistent repeatability — all at
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