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Unlike ionic or small covalent molecules, polymers do not form crystalline solids due to the diffusion limitations of their long-chain structures. However, polymers contain microscopic crystalline domains separated by amorphous domains.
Crystalline domains are the regions where polymer chains are aligned in an orderly manner and held together in proximity by intermolecular forces. For example, chains in the crystalline domains of polyethylene and nylon are bound together by van der Waals...
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A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars
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Influence of Draft Angle Design on Surface Texture-Dimensional Accuracy Coupling in Injection-Molded Commodity and

Hui-Li Chen1, Po-Wei Huang2, Yu-Shan Huang3

  • 1Mechanical Engineering, College of Semiconductor Engineering, CTBC University of Technology, Tainan 74448, Taiwan.

Polymers
|November 13, 2025
PubMed
Summary

Draft angle significantly impacts surface texture clarity in injection molding, with crystalline polymers showing higher roughness and clearer texture replication. Dimensional stability is less affected by draft angle but more by material type.

Keywords:
crystalline and amorphous polymersdimensional accuracydraft angle designplastics injection moldingsurface texture replication

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Area of Science:

  • Injection molding process optimization
  • Polymer science and engineering
  • Surface metrology and characterization

Background:

  • Draft angle is crucial for de-molding and surface quality in injection molding.
  • Demand for textured plastic components is increasing, highlighting the importance of surface texture replication.
  • Limited studies exist on the interaction between polymer material properties and draft angle design.

Purpose of the Study:

  • Investigate the influence of draft angle variation on surface texture quality and dimensional stability.
  • Compare differences between crystalline and amorphous thermoplastics, and commodity vs. engineering plastics.
  • Examine how material characteristics affect surface texture replication in injection-molded parts.

Main Methods:

  • Selected four polymers: polypropylene (PP), polyoxymethylene (POM), acrylonitrile-butadiene-styrene (ABS), and polycarbonate (PC).
  • Designed product geometries with eight draft angles (0° to 3.5°).
  • Analyzed surface texture replication using SEM and profilometry; measured dimensional deformation with optical instruments.

Main Results:

  • Draft angle variation had limited effect on dimensional deformation trends but significantly impacted surface replication clarity.
  • Crystalline polymers generally showed higher surface roughness than amorphous polymers (PP > POM; ABS > PC).
  • Dimensional deformation was greater in crystalline polymers (POM > PP > ABS > PC).
  • Higher surface roughness correlated with clearer texture patterns, while lower roughness led to blurred textures.

Conclusions:

  • Draft angle critically influences surface texture replication clarity in injection molding.
  • Material type (crystalline vs. amorphous, commodity vs. engineering) significantly affects both surface roughness and dimensional stability.
  • SEM analysis confirmed a direct relationship between surface roughness and the distinctness of replicated textures.