Design Guide

Table of Contents
Introduction Gate Geometries . . . . . . . . . . . . . . . . . . . . . 12
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compound Selection . . . . . . . . . . . . . . . . . . . 1 Coring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Part Design Draft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wall Thickness . . . . . . . . . . . . . . . . . . . . . . . . 2 Assembly Methods
Weld Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ultrasonic Welding . . . . . . . . . . . . . . . . . . . . 16
Fiberglass Orientation . . . . . . . . . . . . . . . . . . . 3 Ultrasonic Staking . . . . . . . . . . . . . . . . . . . . 17
Variable Wall Thickness . . . . . . . . . . . . . . . . . 4 Heat Staking . . . . . . . . . . . . . . . . . . . . . . . . 17
Radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Snap Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Ribs and Bosses . . . . . . . . . . . . . . . . . . . . . . 6 Rivet Assembly . . . . . . . . . . . . . . . . . . . . . . 18
Draft and Undercuts . . . . . . . . . . . . . . . . . . . . 7 Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Typical Tolerances . . . . . . . . . . . . . . . . . . . . . 7 Tapped Threads for Bolts . . . . . . . . . . . . . . . 19
Mold Design Self-Tapping Screws . . . . . . . . . . . . . . . . . . 20
Mold Temperature . . . . . . . . . . . . . . . . . . . . . 7 Ultrasonic Inserts . . . . . . . . . . . . . . . . . . . . . .22
Shrinkage . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Molded In Threads . . . . . . . . . . . . . . . . . . . . 22
Tool Steels . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Molded In Inserts . . . . . . . . . . . . . . . . . . . . . 22
Coating Methods . . . . . . . . . . . . . . . . . . . . . . 8 Interference Fit . . . . . . . . . . . . . . . . . . . . . . . 23
Surface Treatments . . . . . . . . . . . . . . . . . . . . 9 Machining . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Sprue Design . . . . . . . . . . . . . . . . . . . . . . . . 10
Runner Design . . . . . . . . . . . . . . . . . . . . . . . 10
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

This document reports accurate and reliable information to the best of our knowledge, but our suggestions and recommendations cannot be guaranteed
because the conditions of use are beyond our control. Information presented herein is given without reference to any patent questions which may be
encountered in the use thereof. Such questions should be investigated by those using this information. Chevron Phillips Chemical Company, LP assumes no
responsibility for the use of information presented herein and hereby disclaims all liability in regard to such use.

For more information and

technical assistance contact:
CHEVRON PHILLIPS CHEMICAL COMPANY, LP
P.O. BOX 3766
HOUSTON, TX 77253
1-877-798-6666

1803-96 K 01 ©Chevron Phillips Chemical Company, LP 2001

1 Ryton® PPS Design Guide

Introduction For many products, designers are often told that their primary objective is to
“do more with less” – less material, less manpower, less money. To meet that
objective, designers work to minimize the number of parts and incorporate
features to streamline assembly, etc. As each design improvement is made,
however, the demands on the performance characteristics of the material the
part is made from also increases.
The most fundamental performance characteristics a designer must
consider during the material selection phase include certain mechanical,
physical, thermal, and electrical properties. As these facts are considered,
the materials that many designers specify to meet this combination of
performance properties are polyphenylene sulfide resins manufactured by
Chevron Phillips Chemical Company, LP and sold under the registered
trademark Ryton (herein “Ryton® PPS”). The combination of unparalleled
thermal, mechanical, physical, and electrical properties of Ryton PPS,
together with its exceptional chemical and flame resistance, means it
performs over a broad range of demanding design requirements.
The design guidelines presented here are intended to provide application
requirements and help designers maximize the versatility of Ryton PPS
engineering thermoplastics in their products. They are the result of direct
experimentation performed at the Plastics Technical Center and our technical
service staff’s experiences in helping customers.

Compound There are two basic series of Ryton PPS compounds from which to select.
Selection
The Fiberglass Reinforced Series
This series includes Ryton PPS R-4, R-404, R-4XT, A-100 and A-200.
The most common determining factor for selecting one of these compounds
is flow length, cross sectional area and strength.
The Fiberglass and Mineral Reinforced Series
This series includes Ryton PPS R-7 and R-10. In addition to the 500°F
(260°C) Heat Deflection Temperature (HDT) at 264 psi and excellent
mechanical strength, these compounds provide enhanced electrical
properties. This feature allows Ryton PPS R-7 and R-10 to be used in a
wide range of applications including electronic devices, switches, and high
density interconnection devices.
Please refer to the engineering properties section for all the specific
mechanical, physical, electrical, chemical, thermal, etc. data for each of the
Ryton PPS compounds.
 Part Design 2

Wall Thickness Material cost and cycle time are directly related to wall thickness. Optimum
part design balances minimum wall thickness versus sufficient strength. The
minimum wall section must be thick enough for the material to fill the mold
under typical processing conditions. With Ryton PPS, as with all resins, it is
important to strive for uniform wall thickness. When this is impractical, parts
should be designed to fill from thick to thin areas. Uniform wall thickness is
also desirable to minimize internal stresses. Where wall thickness must vary,
it should differ by no more than 40% of the thickest wall. Likewise, the
intersection should have a radius of 60% of the thinner wall.
Wall thickness variations can affect the direction of material flow and
therefore shrinkage. Due to the fiberglass and molecular orientation, transverse
shrinkage is roughly double the flow direction shrinkage. For this reason, it is
important that the wall thickness be symmetrical through the cross section of
the part. If thick sections are required to fill the part, the cross section should
be as symmetrical as possible.
Many Ryton PPS part applications have wall thicknesses as thin as 0.015
to 0.020 in. (0.38 – 0.51 mm). For example, one battery pack cover measures
1 in. by 0.500 in. with 0.015 in. walls (25.4 x 12.7 x 0.38 mm). There are
various connectors having 0.018 in. (0.45 mm) walls, and some very small
parts have walls as thin as 0.006 in. (0.15 mm).
In very thick sections, the surface stops shrinking as it solidifies while the
interior bulk continues cooling and shrinking. The difference in shrinkage can
pull the material apart leaving sink marks and shrink voids which reduce overall
strength. Maximum allowable wall thickness depends on the Ryton PPS
compound selected. Most Ryton PPS parts should not have wall thickness
greater than 0.375 in. (9.52 mm). However, the Ryton PPS A-200 compound
resists internal cracking in wall sections as thick as 0.500 in. (13 mm).
Wall sections must be thick enough to allow adequate material flow into the
tool. Figures 1 and 2 illustrate the effect of wall thickness and stock temperature
on spiral flow of Ryton PPS R-4 and R-7. Since spiral flow is not packed at the
end, only 75% of this length should be used for design purposes.
Figure 2 –
Figure 1 – Spiral Flow vs Stock Temperature
Spiral Flow vs Wall Thickness at 0.12 Inch Thickness
28 30
(711) R-4 650°F (343°C) (762)
R-4
24 28
(610) R-7 650°F (343°C) (711)
20 R-4 600°F (316°C) 26
SPIRAL FLOW, in (mm)

SPIRAL FLOW, in (mm)

(508) R-7 600°F (316°C) (660) R-7

16 24
(406) (610)
12 22
(305) (559)
8 20
(203) (508)
4 18
(102) (457)

0 16
0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 (406) 590 610 630 650
(0.51) (1.02) (1.52) (2.03) (2.54) (3.05) (3.56) (4.06) (310) (321) (332) (343)
WALL THICKNESS, in (mm) STOCK TEMPERATURE, °F (°C)
3 Ryton® PPS Design Guide

Weld Lines Weld lines are formed when the melt front divides and then flows back
together. Typically the weld line interface is resin rich since glass fiber does
not cross the interface. This results in lower mechanical strength. If possible,
the weld line should be eliminated or located in an area with lower load
requirements. Gate location is critical in determining weld line location.
If weld lines must bear stress, the part design should compensate for typical
strengths indicated in Figure 3. Weld line strength depends heavily on
processing, so the part and tool design should allow for rapid injection and
thorough packing.
Figure 3 – Weld Line Strength for Ryton® PPS Compounds
12

10
TENSILE STRENGTH, (Ksi)

0
R-4 R-4XT R-7

Fiberglass The orientation of the fiberglass reinforcement affects strength. Ryton PPS
Orientation is stronger in the direction of flow as compared to the transverse direction.
Fiberglass orientation should be utilized to enhance the strength of the part.
Part design should minimize stress in the transverse direction. In some cases,
wall thickness must be increased to compensate for lower transverse strength.
Refer to Figure 4 for transverse versus flow direction strength information.
Figure 4 – Tensile Strength vs Fiberglass Orientation
RELATIVE TENSILE STRENGTH

R-4 R-4 04 R-7

FLOW DIRECTION TRANSVERSE

STRENGTH STRENGTH
 Part Design 4

Variable Wall Some areas of a part may require more strength than others. However, wall
Thickness thickness should be as uniform as possible throughout the part. Radical
variations in wall thickness tend to concentrate stresses – both molded-in and
externally applied. The shrinkage differential between thick and thin sections
causes molded-in stress at the juncture. A uniform wall section creates an
even flow that has uniform shrinkage and minimal molded-in stress.
If wall thickness changes are unavoidable, they should be gradual in order
to minimize stress concentration. Figure 5 is an example of the preferred
method for achieving a variable wall thickness. Coring the part in thick
sections is a good way to ensure uniform wall thickness. Coring will also
provide a means for cost savings in material usage. For further information
on coring refer to the Mold Design section.
Figure 5 – Wall Thickness Transitions

T
FLOW

POOR

T
FLOW

BETTER
3T

T
FLOW

BEST
3T
5 Ryton® PPS Design Guide

Radii Ryton PPS compounds, as is the case with other engineering thermoplastics,
are notch sensitive. Therefore sharp corners should be avoided in part
designs. The optimum fillet radius for Ryton PPS compounds is 0.6T,
where T represents the wall thickness. (Figure 6)
Figure 6 – Design for Radii

0.6 T 0.6 T

POOR BETTER BEST

Abrupt changes in part geometry, like sharp inside corners, cause

amplification of stress in the area of the abrupt change. Quick geometry
variations can promote additional problems as well – such as flow
impedance, molded-in stress and voids. Figure 7 shows the relationship
of stress concentration at a sharp corner as a function of the radius to
wall thickness ratio.
Figure 7 – Typical Stress Concentration Factor
3.5
FORCE
WALL
THICKNESS
R = 0.6T
3.0
STRESS CONCENTRATION FACTOR

2.5

2.0
R = 0.6T
RECOMMENDED DESIGN STANDARD

1.5

1.0
0 0.25 0.5 0.75 1.0 1.25 1.5
RADIUS ÷ WALL THICKNESS RATIO, R / T
 Part Design 6

Ribs and Bosses Proper rib design can increase part strength significantly. Ribs are most
effective in a thin area which must bear a load perpendicular to its plane.
Figure 8 illustrates the optimum relationship between wall thickness, rib
thickness and radius.
Figure 8 – Recommended Rib Design

H
H MAXIMUM = 3T

t = 0.6T
T

1 /2 °
TO 2°
DRAFT

R = 0.6T

In addition to allowing reduced wall thickness and cooling time, ribbing

can improve flow paths to make the part easier to fill. However, ribs that are
too thick can cause sink marks, warpage and cracking. The part design
must incorporate a sufficient radius at the base of the rib.
Boss design should follow the same rules: avoid thick sections and provide
sufficient radius at the base. Figure 9 shows the recommended boss design
for Ryton PPS parts.
Figure 9 – Recommended Boss Design
2.5 TO 3 D

H MAXIMUM = 3T 0.6 T

R = 0.6T

T
0.6 T
7 Ryton® PPS Design Guide

Draft and Ryton PPS compounds flex very little during ejection. Therefore, the part
Undercuts design should avoid significant undercuts and provide sufficient draft to eject
the part without flexure. Short cores and shallow cavities of 3/16 in. (4.76 mm)
or less should have at least 1/4° draft per side. As cavity depth and core
length increases to one or two inches, the draft angle should increase up to
2° per side. Polishing the core and cavity will improve release so a surface
finish of 4 microinch (0.0001 mm) or better should be specified. Polish marks
should parallel the direction of part ejection.
In special cases, an undercut can be useful to retain parts on the core or
cavity during mold opening. The interference should range from 0.0005 to
0.001 in. (0.0127 – 0.0254 mm). Since Ryton PPS compounds are very stiff,
any undercut areas in a mold will experience high wear rates.

Typical Typically, Ryton PPS exhibits very low shrinkage. Dimensional tolerances are
Tolerances very reproducible; therefore, Ryton PPS compounds can be molded to
tolerances as tight as 0.0001 in./in. in optimally gated small parts. More
typical tolerances are 0.0010 in/in. with some large parts requiring tolerances
as high as 0.002 in./in.

Mold Design Mold design is as critical as part design. The best mold designs optimize the
performance properties of Ryton PPS. For example, to produce crystalline
parts, the mold must be designed to operate at 275°F (135°C) or hotter.
It must compensate for material shrinkage within the required level of
dimensional precision. A well planned mold will control the effects of gate
location and melt flow paths on shrinkage, wargape, and part strength. The
tool steel used is also a consideration since it will determine the length of
time the mold will be in service.
Mold Temperature Mold temperature significantly affects crystallinity and thus the long-term
dimensional stability of the part when it is exposed to temperatures above
the glass transition ( Tg ) temperature. (Figure 10)
Figure 10 – Effect of Mold Temperature NOTE: It is very important to
on Crystallinity keep the mold temperature either
90 above 275°F (135°C) or below
80 180°F (82°C). To operate between
70 these temperatures will produce
CRYSTALLINITY INDEX

60 varying resultant dimensions.

50 Parts that are used at high
40 temperatures should be molded
30 using a mold temperature at or
20 above 275°F (135°C).
10
Please refer to the Processing
0
100 140 180 220 260 300 340 380 Guide for specific information
(37) (60) (82) (104) (127) (149) (171) (193)
regarding mold heating/cooling
MOLD TEMPERATURE, °F (°C)
equipment and their manufacturers.
 Mold Design 8

Shrinkage Shrinkage is affected by part weight and thickness, compound type, fiber
orientation, mold temperature, amount of coring in the mold and any
post-molding annealing. Figure 11 shows the expected shrinkage for a
highly cored part.
Figure 11 – Flow and Transverse Shrinkage for Highly Cored Parts
FLOW DIRECTION SHRINKAGE TRANSVERSE SHRINKAGE

SHRINKAGE, in /in OR mm /mm 0.006 0.007

SHRINKAGE, in /in OR mm /mm

0.005
0.006

0.004
0.005
R-4
0.003
0.004
0.002 R-7
R-4
0.003
0.001
R-7
0.000 0.002
0.05 0.07 0.09 0.11 0.13 0.05 0.07 0.09 0.11 0.13
(1.27) (1.78) (2.29) (2.79) (3.30) (1.27) (1.78) (2.29) (2.79) (3.30)

WALL THICKNESS, in (mm)

For any given part, mold shrinkage is less with increasing part weight,
i.e., fully packing out the part decreases shrinkage. Thicker wall sections
generally exhibit higher shrinkage than thinner ones since they hold heat
longer. Mold shrinkage increases somewhat with increasing mold
temperature due to increased crystallization. Parts restrained during molding
by coring will exhibit lower shrinkage than unrestrained parts. Annealing also
affects shrinkage in Ryton PPS parts. Cold-molded parts will develop
substantial crystallinity and shrink considerably if held above 400°F (204°C)
for extended periods.
Conversely, hot-molded parts already have a high level of crystallinity
and so exposure to temperatures above 400°F (204°C) result in very little
additional shrinkage.

Tool Steels For long run production molds, A-2, D-2 or D-7 tool steel hardened to
Rockwell C 60+ is recommended. Of these, A-2 steel is a little more flexible
and forgiving. For low volume runs, P20, S7, and H13 are acceptable softer
steels. Coatings and surface treatments are two methods for achieving higher
wear resistance in long run production molds built from softer tool steels.
Coating Methods Recommended mold coating methods are: slow deposition Dense Chrome
and Electroless Nickel. These coatings provide good mold release character-
istics and fairly long life. It is important to note that steels with a surface finish
of 4 microinch (0.0001 mm) or better experience extended service life.
9 Ryton® PPS Design Guide

Surface Successfully used surface treatments are:

Treatments • Borofuse®
• LSR-1®
• Nitride®

Please consult trade publications such as the “Thomas Register for Metal
Treating Companies”. Figures 12 and 13 show tool wear of different steels
and surface treatments.
Figure 12 – Wear Resistance of Tool Steels
10
9
8
7
WEIGHT LOSS, %

6
5
4
3
2
1
0
P-20 A-2 D-2 FERRO-TIC

SOFT HARD

Figure 13 – Wear Resistance of Surface Treatments

0.20
0.18
0.16

0.14
WEIGHT LOSS, %

0.12
0.10
0.08
0.06

0.04

0.02
0.00
BOROFUSE® NITRIDE® LSR-1®

Prototype tooling is often an excellent way to produce a short production

run of parts and discover the unique facets of producing particular parts.
Prototype tools can be made from a variety of softer steels and aluminum.
The ease of machining the softer metals makes them economical to use
during prototyping. Care must be taken, however, with aluminum tools since
they are more difficult to heat uniformly and cannot withstand high injection
and clamping pressure as well as steel tools.
 Mold Design 10

Sprue Design Standard sprue designs are quite Figure 14 – Standard Sprue Design
acceptable with nominal values
MACHINE LOCATING
of 2° of draft and reverse taper or NOZZLE
RING
Z-cut sprue puller systems. Keep
the runner as short and highly
polished as possible to ease part
removal from the stationary half of
the mold. Figure 14 is a standard
sprue design.
SPRUE
BUSHING

FIXED
HALF

MOVING
HALF

“Z” PULLER

EJECTOR PIN

Runner Design It is most important that the runner system be designed so that the mold
cavities fill uniformly and in a balanced fashion.
Runners of many types can be used successfully with Ryton PPS
compounds. Full round and trapezoidal runners are preferred (Figure 15).
Runners should be designed with cold slug wells.
Figure 15 – Trapezoidal Runner Profiles
15°

“W” “D”
in mm in mm
1/4 6.4 3/16 4.8
D
5/16 7.9 1/4 6.4
7/16 11.1 5/16 7.9
1/2 12.7 3/8 9.5

EQUIVALENT RUNNER DIAMETER “D”

11 Ryton® PPS Design Guide

Multi-cavity molds should have balanced runner systems. On multi-cavity

molds with primary and secondary runners, the primary runner should carry
on beyond the intersection of the secondary runner in order to provide a cold
slug well for the runner flow front. Runner length, however, should be kept at
a minimum (Figure 16).
Figure 16 – Balanced Runner and Cavity

COLD SLUG WELL

Generally, it is good practice with engineering thermoplastics to not use

family mold layouts because of differences in filling patterns. These differences
are sometimes difficult to control and may produce parts with differing
physical and mechanical properties.

Venting To successfully mold Ryton PPS compounds, proper venting is essential.

Poor or improper venting results in hard to fill parts and burning of the part in
areas where gas is trapped. In addition, trapped gas leads to accelerated
mold wear.
Venting can be accomplished with 0.0003 to 0.0005 in. (0.0076 – 0.0127
mm) deep by 0.250 in. (6.35 mm) wide channels cut on the parting line
(Figure 17). Flattened ejector pins can also be used as vents. Stationary vent
pins are not recommended as various substances can clog them over long
part runs. Vacuum venting has been used successfully in areas where a blind
pocket exists. The vacuum is turned on after the mold closes and prior to
the start of the injection cycle. Vented runners have also been used.
 Mold Design 12

Figure 17 – Parting Line Vent Detail

A A

0.25 in
(6.4 mm)

0.06 – 0.09 in LAND

(0.8 – 1.6 mm)
PARTING LINE

DEPTH

SECTION A – A

Gate Geometries The illustration in Figure 18 points out some of the pitfalls of less than
optimum gating methods and offers design solutions.
Part distortion is caused by differential shrinkage. As the molded part
shrinks, internal stresses are developed which distort the part. The greater
the difference in part cross sections, the greater the chance of distortion.
To avoid distortion, the designer should strive to maintain uniformity
throughout the part and minimize weld lines. Since Ryton PPS compounds
are filled compounds, they behave anisotropically. For typical Ryton PPS
compounds, this means parts will shrink about half as much in the flow
direction as perpendicular to the direction of flow.
Figure 18 – Gate Geometries
WELD LINES

a. b. c. d.
WELD LINES EDGE GATE 3-PIN GATES SPOKE GATE DIAPHRAGM GATE
13 Ryton® PPS Design Guide

Gates A variety of different gating methods Figure 19 – Minimum Gate Sizes

are suitable for molding Ryton PPS

MINIMUM GATE THICKNESS, 0.100 in WIDE BY:

0.050
compounds. A graph of minimum
tab-gate size versus part weight is 0.040

shown in Figure 19. This graph

assumes a gate width of 0.100 in. 0.030

(2.54 mm) and depicts the relative

0.020
need for increasing gate thickness (t)
as part weight increases. Success
0.010
has been shown with center, sprue,
tab, flash, round, disk, submarine, 0.000
and spoke gates. The placement of 0 20 40 60 80 100 120

the gate is essential in determining PART WEIGHT, grams

the potential strength and

dimensional stability of the part.
Small parts can usually be gated in a
single location to prevent weld lines. t (GATE THICKNESS)
If the part cannot be molded without
weld line(s), the weld line(s) should
0.100 in
be placed in the thickest section of
the part or in areas where there is
minimal stress.
The following list represents the majority of gating choices available:
Center/Sprue Gate – Efficient, works well on parts where concentricity is
important or parts with dome shapes (Figure 20).
Pin Gate – Used much like a sprue gate, this gate can be used with
multi-cavity tooling and provides automatic separations of part from runner
(Figure 21).
Fan Gate – Good for uniform polymer flow front into a part similar to a
flash gate (Figure 22).
Diaphragm (Disk) Gate – Ideal for producing highly concentric cylindrical
parts without weld lines (Figure 23).
Spoke Gate – Can be used in parts which are too large for a diaphragm
gate. Odd number of spokes should be used so that gates are not opposite
one another. In addition, gates should be positioned such that weld lines
form in the areas of thickest cross section (Figure 24).
Flash Gate – Good for parts with large flat surfaces requiring minimum
warpage (Figure 25).
Edge Gate – Most commonly used, allows high degree of fiber orientation,
generally seen on multi-cavity molds requiring moderate precision in
tolerances (Figure 26).
Tunnel (Submarine) Gate – Submarine gates have been used
successfully with Ryton PPS compounds; however, special consideration
must be given to the design. The tunnel included angle should be 30 – 35°
and the center line of the tunnel should be 25 – 30° from a line drawn
perpendicular to the mold parting line. Figure 27 presents a recommended
submarine gate design. The tunnel must be well polished with no undercuts.
 Mold Design 14

Figure 20 – Sprue Gate Figure 21 – Pin Gate

SPRUE POLISH TO A RUNNER
SPHERICAL RADIUS PLATE
T

PART R = 0.6 T
MOLD
PARTING CAVITY
LINE RETAINER
PLATE
DRAFT
1° – 3°
LAND LENGTH

GATE
SIZE

Figure 22 – Fan Gate Figure 23 – Diaphragm Gate

A A A A
RUNNER

GATE

RUNNER
EJECTOR PIN

PART
GATE WALL
SECTION A – A

Figure 24 – Spoke Gate DIAPHRAGM

GATE
A SPRUE

SECTION A – A
A

Figure 25 – Flash Gate

GATE
A A
SPOKE
GATE

PART WALL

SECTION A – A RUNNER
EJECTOR PIN

SECTION A – A

Figure 27 – Tunnel Gate

GATE AN
GL E
30°
– 35°
CENTE
Figure 26 – Edge Gate RLIN
E
ANGL
0.020 in 25° – 3 E
0°
(0.51 mm)

SEE MINIMUM KNOCKOUT PIN

GATE SIZE
1 – 11/2 D
15 Ryton® PPS Design Guide

Coring Thick part sections should be cored to provide uniform wall thickness. This
design practice will avoid sink marks and voids, reduce stress and cycle
time, and offer material savings. Cores which extend into the cavity will be
subject to high pressure; therefore, these cores should generally have a
minimum diameter of D=0.050 in. (1.27 mm) and should not extend more
than 2 D unless they pass entirely through the cavity. Refer to Figure 28.

Figure 28 – Coring Problems and Solutions

BEFORE CORING REDESIGN

CORE EQUALLY
FROM BOTH SIDES

SINKS

SINKS

T 0.6 T

SINK

Draft Ryton PPS compounds flex very little during ejection. Therefore, the part
design should provide sufficient draft to eject the part without flexure. Short
cores and shallow cavities of 3/16 in. (4.76 mm) or less should have at least
1/4° draft per side. As cavity depth and core length increases to one or two
inches, draft angle should increase up to 2° per side. Polishing the core and
cavity will improve release so specify a surface finish of 4 microinch (0.0001
mm) or better. Polish marks should parallel the direction of part ejection. This
is typically referred to as draw polishing.
 Assembly Methods 16

Assembly Most products incorporate several functions that require different levels of
Methods performance or dimensional precision. In many cases, Ryton PPS compounds
can meet all these requirements, allowing the designer to combine these
functions into a single molding. When part geometry or functional needs
necessitate more than one molding or material, the components should be
designed to minimize the cost and complexity of assembly procedures.
Ryton PPS parts may be assembled using a variety of techniques, each
requiring certain design considerations. Procedural details are presented in
other Ryton PPS literature.
Ultrasonic Ryton PPS compounds are relatively easy to weld together. Joint design is,
Welding however, critical to the finished part strength. A shear joint is the best overall,
although the step joint has been used successfully with Ryton PPS R-4. The
shear joint will generally be six times stronger than the step joint. There are
many types of joint designs. Typical joint designs for the shear and step joints
including relative dimensions are shown in Figures 29 and 30.
When welding shear joints, use high power with a high amplitude booster,
low pressure, and slow horn speed. When welding the parts, caution should
be used since too high an amplitude and/or too long an application time could
destroy the part. Refer to Figure 29.
Figure 29 – Shear Joint for Some of the more common joint design
Ultrasonic Welding mistakes to avoid are:
BEFORE WELD
1. Joints which are too tight or too close
together which prevent adequate vibration.
2. The section transmitting the ultrasonics
R = 0.6 W being too thin as it may crack under the
W
W = 0.050 in high amplitude level.
(1.3 mm)
MINIMUM
PILOT
3. Too large a step requiring a high instant
power which may destroy the part.
DEPTH
OF WELD 4. An assembly in which the highest part
0.015 – 0.03 in
(0.4 – 0.8 mm) does not vibrate.
5. An energy director design which will
prevent a homogenous weld.
INTERFERANCE =
0.012 – 0.015 in
(0.3 – 0.4 mm)
CLEARANCE =
0.002 – 0.005 in
(0.05 – 0.13 mm) Figure 30 – Step Joint for Ultrasonic Welding
AFTER WELD BEFORE WELD

W
AFTER WELD

W/3 H
W/3

C = 0.002 – 0.005 in (0.05 – 0.13 mm)

H = 0.008 – 0.025 in (0.2 – 0.6 mm)
17 Ryton® PPS Design Guide

Ultrasonic Ultrasonic staking is an assembly method that uses the controlled melting
Staking and reforming of a plastic stud or boss to capture or lock another component
of the assembly. The plastic stud protrudes through a hole in the component,
then the high frequency vibrations of the ultrasonic horn are imparted to the
top of the stud. The stud melts and fills the volume of the horn cavity to
produce a head, locking the component in place. The progressive melting
of plastic under continuous but generally light pressure forms the head.
Ultrasonic staking does cause some reduction in tensile strength of the
reformed stud.
The advantages of ultrasonic staking include short cycle time, tight
assemblies with virtually no tendency for recovery, the ability to perform
multiple stakes with one horn, repeatability and control over the process,
design simplicity, and the elimination of consumables such as screws.
There are two head-forms that will satisfy the requirements of a majority of
applications (Figure 31). The first, generally considered standard, produces a
head having twice the diameter of the original stud, with a height 1/2 the stud
diameter. The second, referred to as a low-profile, has a head diameter 11/2
times the stud diameter, with a head height 1/4 the size of the head diameter.
Figure 31 – Ultrasonic Staking Methods

d d

D D

H H

2D 1.5 D

1 /2 D 1 /4 D

Heat Staking Heat staking is very similar to ultrasonic staking, and has many of the same
advantages plus greater strength.
Testing has demonstrated that amorphous parts (cold molded) stake
more easily and exhibit more strength than crystalline (hot molded) parts. The
rate of heat transfer is controlled by adjusting the interdependent variables of
the tip temperature and downward pressure. Too much pressure and/or too
low a temperature will crack the post before melt-deformation can occur.
The optimum process conditions for a typical 1/8 in. (3.18 mm) diameter post
might be, for an amorphous part, a tip temperature of 590°F (310°C). For a
crystalline part, use a tip temperature of 620°F (327°C). The downward force
 Assembly Methods 18

is typically 150 lbs. (68 kg) applied for 40 seconds. Since the staked area will
be amorphous after the melt/deformation, the assembly should be annealed
at 400°F (204°C) for 2 hours if the application requires a fully crystalline part.
The heat staking tip is designed in the same manner as the horn head
for an ultrasonic staking unit. However, since all glass reinforced compounds
can be abrasive, we recommend the staking tip be made of a hardened
steel with a Rockwell C rating of 60 or greater.
Snap Fit The most convenient method of assembling plastic parts is the snap fit.
The savings in assembly costs more than offset the increase in tooling costs
required by this technique. Studies have shown that the high strength and
ridgity of Ryton PPS compounds provide good holding strength with a
minimum of flex and interference. Figure 32 details the guidelines for the
design of snap fit members for different Ryton PPS compounds.
Figure 32 – Snap Fit Design Parameters

CALCULATE MAXIMUM DEFLECTION BY: ε L2

∆=
t 3C
WHERE: ∆ = DEFLECTION AT BREAK*
L = LENGTH
C = t /2
t = THICKNESS
∆ ε = 0.018 FOR R-4XT
0.014 FOR R-4
0.013 FOR A-200
0.010 FOR R-7

L *USE 75% FOR ONE TIME ASSEMBLY

USE 50% FOR MULTIPLE ASSEMBLIES

Rivet Assembly Ryton PPS can be successfully assembled using semi-tubular style rivets.
The definition of a semi-tubular rivet is a rivet whose mean hole depth,
measured on the wall, does not exceed 112% of its mean body diameter.
This design will put less stress on the molded parts, especially if the distance
between the hole and the underside of the head is the same as the
combined material thickness. In order to ensure that minimum stress is
placed on the molded parts during riveting operations, it is essential that the
rivet setter be adjusted to exert the minimum impact required to clinch the
rivet. Even more successful are the (Tommel) rivet setting machines that
round over the metal on the bottom of the rivet. This places even less stress
on the part. Refer to Figure 33.
Figure 33 – Example Rivets

SOLID HOLLOW SEMI-TUBULAR

19 Ryton® PPS Design Guide

Adhesives Adhesive bonding is a versatile method of joining like or dissimilar materials.

Holes, rivets, clamps, and screws have a tendency to cause stress points in
concentrated areas. Adhesives tend to distribute the load over the entire
area, thus virtually eliminating localized stress areas. There are many
adhesives that will bond Ryton PPS compounds, provided the surface is
properly prepared to allow the adhesive to wet the surface. The adhesive is
selected to best meet the need for the application in which the product will
ultimately be used.
In each adhesive application, the following criteria must be considered:
1. Characteristics of the materials to be joined
2. Surface preparation
3. Joint design
4. Adhesive selection and handling
5. Application
6. Cure of the adhesive/adhered couple
7. Ultimate strength and environmental performance of the “adhesively
joined” fabricated part or structure.
Surface preparation and adhesive selection is discussed in our Technical
Service Manual TSM-283.
Tapped Threads It is often desirable to assemble plastic components to each other or to
for Bolts different materials using bolts. In most applications where repeated assembly
and disassembly is not required, Ryton PPS moldings with tapped threads
work very well.
To characterize the bolt holding strength of Ryton PPS compounds, holes
were drilled in injection molded 0.625 in. (15.9 mm) thick Ryton PPS R-4 and
R-10 7006A slabs. Three hole sizes were tapped for a variety of common
threads, ranging from 4-40 to 1/4-20 bolts. The three hole sizes chosen
were, one hole size smaller, one hole size larger, and the recommended hole
size for steel threads, as shown in the “Machinery’s Handbook” for each bolt.
The bolts were then screwed into the hole to three depths, four bolt
diameters (except the 1/4-20), two bolt diameters, and three turns. Samples
were then pulled in an Instron to measure the force required either to pull the
bolt from the hole, or to break the bolt.
The data in Table I demonstrate that tapped holes in Ryton PPS
R-10 7006A have excellent bolt holding power. Bolts screwed in to a depth
of four bolt diameters equaled or exceeded the tensile strength of brass and
mild steel bolts. Bolts screwed in three turns and those at two bolt diameters
also had excellent strength.
 Assembly Methods 20

Tests using various drill sizes demonstrated that a threaded oversize hole
required more force to pull the bolt than threads in a regular hole or in an
undersize hole. For maximum strength, therefore, holes should be drilled
with at least one drill size larger than that used in steel. For maximum holding
power, bolts should be screwed in three to four diameters rather that the two
diameters normally recommended for metals. To prevent cross-threading,
lead-in holes should be chamfered.
Tests have shown virtually no wear on taps after threading 25 holes.
However, Ryton PPS R-4 and R-10 7006A are heavily reinforced, and like all
reinforced materials, are abrasive to machine and cutting tools. Therefore,
relatively short tap life should be expected.

Table I – Bolt Holding Strength in Ryton® PPS R-10 7006A

Pound Force (N)
Bolt Size Drill Size Bolt Depth to Pull Out Bolts
4-40, Mild Steel No. 43 3 Turns 184 (818)
0.112 in (2.84 mm) 0.089 in (2.26 mm) 0.224 in (5.69 mm) 413 (1837)
0.448 in (11.38 mm) 3921 (1744)
6-32, Brass No. 36 3 Turns 244 (1085)
0.138 in (3.51 mm) 0.106 in (2.69 mm) 0.276 in (7.01 mm) 5721 (2544)
0.522 in (13.26 mm) 5991 (2664)
8-32, Brass No. 29 3 Turns 236 (1050)
0.164 in (4.17 mm) 0.136 in (3.45 mm) 0.328 in (8.33 mm) 7611 (3385)
0.625 in (15.88 mm) 7611 (3385)
10-24, Mild Steel No. 25 3 Turns 366 (1628)
0.190 in (4.83 mm) 0.149 in (3.78 mm) 0.380 in (9.65 mm) 11332 (5040)
0.625 in (15.88 mm) 14081 (6263)
10-32, Brass No. 21 3 Turns 274 (1219)
0.190 in (4.83 mm) 0.159 in (4.04 mm) 0.318 in (8.08 mm) 9202 (4092)
0.625 in (15.88 mm) 13701 (6094)
1/4-20,Mild Steel No. 7 3 Turns 560 (2491)
0.250 in (6.35 mm) 0.210 in (5.33 mm) 0.550 in (13.97 mm) 24602 (10942)
0.625 in (15.88 mm) 26171 (11640)
1
= Bolts Broke
2
= Stripped Threads

Self-Tapping The excellent creep resistance of Ryton PPS makes it well suited for assembly
Screws with self-tapping screws. Due to the hardness of Ryton PPS compounds,
thread cutting types, rather than thread forming types, perform best. The hole
size recommended by the “Machinery’s Handbook” for phenolformaldehyde
thermosets should be used.
To demonstrate the holding power, and torque retention, of self-tapping
screws, Tables II, III and IV were assembled for Ryton PPS R-4 and
R-10 7006A. This data indicates that Ryton PPS is an excellent choice for
screw assembly techniques.
21 Ryton® PPS Design Guide

Table II – Self-Tapping (Thread Cutting) Screw Holding Power in Ryton® PPS R-4
Screw Type Thread Driving Undriving Stripping Avg. Holding Suggested
and Size Engagement Torque Torque Torque Load Tensile Drill Size
Mild Steel in (mm) in•lbf (Nm) in•lbf (Nm) in•lbf (Nm) Pounds•Force (N) in (mm)
Type F
#4-40 3/16 (4.76) 2 (0.2) 1 (0.1) 9 (1.0) 164 (729) #40 0.0980 (2.49)
4-40 5/16 (7.94) 4 (0.5) 2 (0.2) 15 (1.7) 477 (2122) 40 0.0980 (2.49)
6-32 1/4 (6.35) 9 (1.0) 6 (0.7) 19 (2.1) 359 (1597) 32 0.1160 (2.95)
6-32 5/16 (7.94) 11 (1.2) 9 (1.0) 33 (3.7) 544 (2420) 32 0.1160 (2.95)
8-32 5/16 (7.94) 10 (1.1) 10 (1.1) >50 (>5.6) 612 (2722) 27 0.1440 (3.66)
8-32 1/2 (12.7) 21 (2.4) 21 (2.4) >50 (>5.6) 1360 (6049) 27 0.1440 (3.66)
10-24 5/16 (7.94) 18 (2.0) 15 (1.7) 45 (5.1) 492 (2188) 20 0.1610 (4.09)
10-24 1/2 (12.7) 24 (2.7) 24 (2.7) >50 (>5.6) 1103 (4906) 20 0.1610 (4.09)
10-32 5/16 (7.94) 28 (3.2) 28 (3.2) >50 (>5.6) 745 (3314) 20 0.1610 (4.09)
10-32 1/2 (12.7) 50 (5.6) 50 (5.6) >50 (>5.6) 1132 (5035) 20 0.1610 (4.09)

Table III – Self-Tapping Screw Holding Power in Ryton® PPS R-10 7006A
Pounds
Screw Drill Thread Driving Undriving Stripping Force
Size Size Engagement Torque Torque Torque (N) to Pull
in (mm) in (mm) in (mm) in•lbf (Nm) in•lbf (Nm) in•lbf (Nm) Out Screw
4-40, No. 40 3/16 (4.76) 2 (0.2) 1 (0.1) 9 (0.1) 2212 (983)
0.112 (2.84) 0.098 (2.49) 5/16 (7.94) 4 (0.5) 3 (0.3) 14 (1.6) 448 (1993)
6-32, No. 32 1/4 (6.35) 8 (0.9) 6 (0.7) 18 (2.0) 3762 (1672)
0.138 (3.51) 0.116 (2.95) 5/16 (7.94) 9 (1.0) 7 (0.8) 24 (2.7) 593 (2638)
8-32, No. 27 5/16 (7.94) 10 (1.1) 8 (0.9) >50 (>5.6) 5542 (2464)
0.164 (4.17) 0.144 (3.66) 1/2 (12.7) 16 (1.8) 15 (1.7) >50 (>5.6) 1263 (5618)
10-24, No. 20 5/16 (7.94) 16 (1.8) 11 (1.2) >50 (>5.6) 5022 (2233)
0.190 (4.83) 0.161 (4.09) 1/2 (12.7) 31 (3.5) 24 (2.7) >50 (>5.6) 1297 (5769)
10-32, No. 20 5/16 (7.94) 28 (3.2) 25 (2.8) >50 (>5.6) 762 (3389)
0.190 (4.83) 0.161 (4.09) 1/2 (12.7) >50 (>5.6) 41 (4.6) >50 (>5.6) 1345 (5983)
1
= Accurate readings could not be obtained above 50 in•lbf (5.6Nm) of torque.
2
= Failures resulted from brittle fracture of Ryton PPS.

Table IV – Torque Retention of Self-Tapping Screws in Ryton® PPS R-4

Unscrewing Torque Unscrewing Torque
Application Torque After 24 h at Room Temp., After 24 h at 160°F (71°C),
in•oz (Nm) in•oz (Nm) in•oz (Nm)
13 (0.092) 12.3 (0.087) 11.7 (0.083)
16 (0.113) 14.3 (0.101) 12.0 (0.085)
20 (0.141) 17.7 (0.125) 16.7 (0.118)

Screw Data
Screw Length 0.196 in. (4.98 mm) Height of Head 0.071 in. (1.80 mm)
Screw Diameter 0.073 in. (1.85 mm) Head Diameter 0.118 in. (3.0 mm)
Drilled Hole Size 0.059 in. (1.50 mm) Contact Area of Head 0.007 in.2 (4.5 mm2)
 Assembly Methods 22

Ultrasonic Inserts Like other thermoplastics, Ryton PPS can be conveniently assembled using
ultrasonic inserts. Table V shows how a 0.625 in. (15.9 mm) Ryton PPS
R-10 7006A slab was used to develop pull data on three common sizes of
inserts. Inserts of these types are recommended when repeated disassembly
is required, and good pull-out strength is desirable. Figure 34 shows design
recommendations for other common inserts.
The tapered hole is specified for the following reasons:
1. Positioning of the insert is faster, more accurate and ensures proper
alignment every time.
2. Places the insert in a “partially installed” position in the hole,
permitting more rapid installation because the volume of plastic
which must be displaced is decreased.
3. Provides the best release of the plastic part from the mold.
Table V – Specifications for Figure 34 – Design Recommendations
Ultrasonic Inserts for Ultrasonic Inserts
Insert 8°
Size Length D Max. E Max.
EMAX
No. 0 & No. 2 0.115 0.121 0.126
0.188 0.110 0.126
No. 4 0.135 0.156 0.162 MINIMUM DEPTH =
INSERT LENGTH +
0.219 0.144 0.162 0.030 in (0.762 mm)

No. 6 0.150 0.202 0.209

0.250 0.188 0.209
DMAX
No. 8 0.185 0.229 0.237
0.312 0.211 0.237
No. 10 0.225 0.270 0.280
0.375 0.249 0.280
1/4 in. 0.300 0.352 0.366
0.500 0.324 0.366
5/16 in. 0.335 0.434 0.451
0.562 0.404 0.451
3/8 in. 0.375 0.526 0.543
0.625 0.491 0.543
(All dimensions in inches)

Molded-In Because of the excellent processability of Ryton PPS, molded-in threads

Threads can be designed into most parts. This will eliminate the need for expensive
secondary machining operations. Molding in the threads should also provide
superior performance, as compared to machined threads, due to the normal
skin effect on injection molded parts. Table VI has the pull-out values for
molded-in threads.
Molded-In Inserts Because of the excellent processability of Ryton PPS, molded-in inserts can
be designed into many parts. Molded-in inserts may be used when repeated
assembly and disassembly of parts is required. Since Ryton PPS easily
molds around inserts, excellent pull-out strengths should be expected.
23 Ryton® PPS Design Guide

Table VI –
Holding Power of Various Fastening Methods in Ryton® PPS R-10 7006A
Pound Force
Fastening Fastener Thread Size Drill Size Engagement (N) to Pull
Method Type in (mm) in (mm) in (mm) from Sample
Ultrasonic Dodge® 6-32
Insert Ultrasert II* 0.138 0.188 0.250 383
(3.51) (4.78) (6.35) (1704)
Ultrasonic Dodge® 10-32
Insert Ultrasert II* 0.161 0.249 0.375 785
(4.09) (6.32) (9.53) (3492)
Molded 1/4-20
Threads 0.250 – 0.500 1633
(6.35) – (12.7) (7264)
Molded Yardley® (Brass) 1/4-20
Inserts Standardized 0.250 – 0.500 3087
(6.35) – (12.7) (13731)

Interference Fit The strength and modulus of Figure 35 – Pin Retention vs

Ryton PPS compounds make them Pin Interference
12
suitable for retention of interference (5.45)
R-4
fit components. Figure 35 details 10
(4.55)
typical pin retention with simple PIN RETENTION, lb (kg)

8
upset pin interference. Generally (3.64)
interference fits should be limited 6
R-7
(2.73)
to 0.004 in. (0.101 mm) with
4
Ryton PPS R-4, and 0.0035 in. (1.82)
(0.088 mm) with R-7 and R-10. 2
(0.91)

0
0.0010 0.0014 0.0018 0.0022 0.0026 0.0030
(0.0250) (0.0356) (0.0457) (0.0559) (0.0660) (0.0762)
PIN INTERFERENCE, in (mm)

Machining Because of its exceptional mechanical properties, Ryton PPS can be readily
machined with conventional metal working tools. A high degree of precision
can be obtained with Ryton PPS while using moderate cutting speeds and
fast feed rates. It is recommended that carbide tipped tools be used for
machining all Ryton PPS compounds.
In general, the best surface speed will be in the moderate speed range of
80 to 100 SFM (0.4 to 0.5 m/s).
The rate of travel should be relatively fast. A slow feed results in excess
abrasion by the tool and will tend to give poor surface appearance. If a
coolant is desired, ethylene glycol (antifreeze) works well.
Although fairly deep cuts of up to 1/8 in. (3.17 mm) can be made, finish
cuts should take off no more than 0.005 in. (0.127 mm) of material. The final
cut should be as little as 0.001 in. (0.0254 mm).