Influence of Draft Angle Design on Surface Texture–Dimensional Accuracy Coupling in Injection-Molded Commodity and Engineering Polymers with Semi-Crystalline and Amorphous Characteristics

In injection molding, draft angle design plays a critical role in ensuring smooth de-molding and maintaining surface quality. With the growing emphasis on aesthetics and the increasing demand for the appearance of plastic products, the need for textured plastic components has continuously risen. The coupling between surface texture replication and dimensional accuracy has become an important indicator of product performance. However, systematic studies on the interaction between different polymer materials and draft angle design remain limited. This study aims to investigate the influence of draft angle variation on the surface texture quality and dimensional stability of injection-molded parts by comparing the differences between crystalline and amorphous thermoplastic materials, as well as between commodity and engineering plastics. Four representative polymers, namely polypropylene (PP), polyoxymethylene (POM), acrylonitrile-butadiene-styrene (ABS), and polycarbonate (PC), were selected to examine the impact of material characteristics on surface texture replication after molding. In addition, product geometries incorporating eight draft angles (0° to 3.5°) were designed. Surface texture replication was analyzed using scanning electron microscopy (SEM) and surface profilometry, while dimensional deformation was measured with a high-precision optical measuring instrument. The results show that draft angle variation has a limited influence on the overall trend of dimensional deformation, but it has a significant effect on the clarity of surface replication. Crystalline polymers exhibited generally higher surface roughness than amorphous polymers, and the distinction between commodity and engineering plastics, particularly those requiring higher processing temperatures, also led to higher roughness (PP > POM; ABS > PC). Dimensional deformation was more pronounced in crystalline polymers (POM > PP > ABS > PC). SEM observations further confirmed that higher roughness corresponded to clearer and more distinguishable texture patterns, whereas lower roughness resulted in blurred or indistinct textures.