BY: BEN BALADYA

PLASTIC PART AND MOLD DESIGN GUIDE


CONTENTS
1. INTRODUCTION………………………………….…… 3
2. DESIGN PROCESS….……………………………..… 4
3. PLASTIC MATERIALS…………………………….…. 5
3.1 Classification of Plastic Materials…………….…. 5,6
3.2 Defining Material Requirements…...................... 7,8
3.3 Common Thermoplastic Materials ………….….. 9
4. MOLD PART DESIGN GUIDELINES …………….…10
4.1 Parting Lines ……………………………………... 10
4.2 Wall Thickness …………………………………… 11
4.3 Draft Angle ……………………………………….. 12
4.4 Ribs……….……………………………………….. 13
4.5 Bosses …………………………………………. 14 - 16
4.6 Gussets …………………………………………… 17
4.7 Sharp Corners ……………………………………. 18
4.8 Holes and Cores …………………………………. 19
4.9 Undercuts ……………………………………… 20 - 23
4.10 Molded-in Threads ………………………….... 24 - 25
4.11 Lettering …………………………………………… 26
5. THERMOPLASTIC PROCESSING METHODS ……. 27
5.1 Injection Molding ………………………………….. 27
5.2 Polymer Extrusion …………………….................. 28
5.3 Thermoforming ……………………………………. 29
5.4 Extrusion Blow Molding ………………………….. 30
5.5 Injection Blow Molding …………………………… 31
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6. PAINTING, PLATING AND DECORATING...…….…32
6.1 Painting …………………………………….......32 - 33
6.2 Plating …………………………………………..… 34
6.2.1 Electroplating ……………………….. …..34 - 35
6.2.2 Vacuum Metallization…………………….... 36
6.2.3 EMI / RFI Shielding………………………….37
6.3 Decorating/Printing ……………………………… 38
6.3.1 Pad Printing ………………………………… 38
6.3.2 Screening ………………………………….. 38
6.3.3 Laser Printing ………………………………. 39
6.3.4 Hot Stamping ………………………………. 39
6.3.5 Labels and Decals …………………………. 40
7. DESIGN FOR ASSEMBLY …....................................41
7.1 Part Consolidation …………………………………41
7.2 Mechanical Fasteners ……………….................. 42
7.3 Snap Fit Joints ………………………………….43 - 47
7.4 Press Fit Assembly …………………………..….. 48
7.5 Adhesive Bonding ………………………………49 - 50
7.6 Bolts, Nuts and Machine Screws ………………..51
7.7 Self-Tapping Screws ……………………………..52
7.8 Inserts ……………………………………………...53
7.9 Ultrasonic Welding ………………………………54 – 55
7.10 Thermoplastic Staking …………………………..56
7.11 Electromagnetic Welding ……………………….57
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 PLASTIC PART AND MOLD DESIGN GUIDE

1. INTRODUCTION

Injection molding is a process in which solid thermoplastic

resin pellets are melted, injected into a mold, and then
cooled back to a solid state in a new form. During both the
injection and cooling stages of the manufacturing process,
there are several factors which will affect the quality of the
final product as well as the repeatability of the manufacturing
process. Following a few important guidelines during part
design will help minimize problems during molding and in the
field. Although it is not always possible to follow all of these
guidelines, outlined on the following pages are some of the
most fundamental recommendations when designing parts
for injection molding.

The design guide focuses primarily on Plastic part and Mold design.
It is intended to give the product designer the basic guideline to design
a product that is of high quality and easy to manufacture plastic parts.
It includes chapters on the Plastic materials, Part Design Considerations,
Design for Assembly and some topics on Painting, Plating, and Decorating.

This document is intended to be a guide and not an absolute specification.

The intent is to design and build a tool that will produce a part as
close to specification as possible, require the minimum of correction,
and to achieve this goal in a timely and professional manner.

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2. DESIGN PROCESS

When designing and developing parts, focus on defining and maximizing part function and appearance,
specifying actual part requirements, evaluating process options, selecting an appropriate material, reducing
manufacturing costs, and conducting prototype testing. For the reasons stated above, these efforts should
proceed simultaneously. The design process can be simplified by following a three stage approach where
material, design and fabrication decisions are made in parallel. The following guidelines are reminders of good
design practice aimed at producing quality injection molded parts.

Preliminary (Design) stage

•Define requirements Manufacturing stage
•Establish conceptual geometry •Design, build and evaluate a tool
•Select materials •Cavity filling analysis
•Select Fabrication method •Manufacturing equipment selection
•Perform Feasibility Analysis •Part testing
•Decision to move forward •Customer evaluation
Engineering stage
•Complete detailed part design
•Fabrication decisions
•Material decisions
•Prototype testing
•Evaluation and redesign

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3. PLASTIC MATERIALS
3.1 CLASSIFICATION OF PLASTIC MATERIALS
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PLASTICS are man-made materials and it is any of a wide
range of synthetic or semi-synthetic organic solids that are
moldable. They are made up of long chains of large molecules.
Each molecule consists of many units of organic chemicals,
thus called a polymer (many units), or macromolecules.
At room temperature, the material is solid and rigid, and it can
withstand significant structural load. Some of the materials
retain rigidity at relatively high temperatures and can replace
metallic components in such high temperature environments as
automobile underhood applications. These plastics are classified
as Thermoplastic and Thermoset.
THERMOPLASTIC, also known as a thermosoftening
plastic,is a polymer that becomes pliable or moldable above a
specific temperature, and returns to a solid state upon cooling.
Most thermoplastics have a high molecular weight, whose
chains associate through intermolecular forces; this property
allows thermoplastics to be remolded because the
intermolecular interactions spontaneously reform upon cooling.
THERMOSET materials are usually liquid or malleable prior to
curing and designed to be molded into their final form, or used
as adhesives. Others are solids like that of the molding
compound used in semiconductors and integrated circuits (IC).
Once hardened a thermoset resin cannot be reheated and
melted back to a liquid form.
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3. PLASTIC MATERIALS
THERMOPLASTIC material can be classified into two categories:
Figure 1
CRYSTALLINE and AMORPHOUS. Figure 1 shows the molecular
arrangement of polymer chains.

Semi-crystalline materials
Semi-crystalline materials have an ordered structure in which adjacent polymer
molecules are positioned in a definite geometry. These materials have a sharp
melting point and are typically solvent resistant. These materials are also anisotropic AMORPHOUS
which means they shrink differently in the flow and transverse directions.
Amorphous Materials SEMI-
Amorphous material are not crystalline, and adjacent molecules have a CRYSTALLINE
random structure. These materials have no identifiable “melting point” but
progressively soften through a broad temperature range. Unfilled amorphous
materials are typically isotropic, shrinking equally in the flow and tranverse
directions. Even fiber-filled amorphous materials typically have low shrink
and good dimensional control.
Amorphous resins are generally chosen over crystalline resins when tight
tolerances are required. More importantly than the magnitude of shrinkage
is the degree of isotropic shrinkage in the material. If a material shrinks anisotropically
(e.g., shrinkage in transverse direction is different than shrinkage in flow direction)
then differential shrinkage in the part will result.
This differential shrinkage in the part may cause
part warpage. A material which shrinks
isotropically will minimize differential
shrinkage and stress in the part and
maximize part dimensional stability.

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3. PLASTIC MATERIALS
3.2 DEFINING MATERIAL REQUIREMENTS
Thoroughly ascertain and evaluate your part and
material requirements, which will influence both part
design and material selection. When evaluating these
requirements, consider more than just the intended,
end-use conditions and loads: Plastic parts are often
subjected to harsher conditions during manufacturing
and shipping than in actual use.
Mechanical Loading
Carefully evaluate all types of mechanical loading including
short-term static loads, impacts, and vibrational or cyclic
loads that could lead to fatigue. Ascertain long-term loads
that could cause creep or stress relaxation. Clearly identify
impact requirements.
Temperature
Many material properties in plastics -impact strength, modulus,
tensile strength, and creep resistance to name a few —
vary with temperature. Consider the full range of end-use
temperatures, as well as temperatures to which the part will
be exposed during manufacturing, finishing and shipping.
Remember that impact resistance generally diminishes at
lower temperatures.
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Chemical Exposure
Plastic parts encounter a wide variety of chemicals
both during manufacturing and in the end-use
environment, including mold releases, cutting oils, de-
greasers, lubricants, cleaning solvents, printing dyes,
paints, adhesives, cooking greases, and automotive
fluids. Make sure that these chemicals are compatible
with your selected material and final part.
Electrical Performance
Note required electrical property values and nature of
electrical loading. For reference, list materials that are
known to have sufficient electrical performance in your
application. Determine if your part requires EMI
shielding or UL testing.
Radiation
A variety of artificial sources — such as fluorescent
lights, high-intensity discharge lamps, and gamma
sterilization units — emit radiation that can yellow
and/or degrade many plastics. If your part will be
exposed to a radiation source, consider painting it,
or specifying a UV-stabilized resin.
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3. PLASTIC MATERIALS
3.2 DEFINING MATERIAL REQUIREMENTS
Weather Resistance
Temperature, moisture, and UV sun exposure affect plastic
parts’ properties and appearance. The end-use of a product
determines the type of weather resistance required. For
instance, external automotive parts such as mirror housings
must withstand continuous outdoor exposure and perform in the
full range of weather conditions. Additionally, heat gain from sun
on dark surfaces may raise the upper temperature requirement
considerably higher than maximum expected temperatures.
Conversely, your requirements may be less severe if your part is
exposed to weather elements only occasionally. For example,
outdoor Christmas decorations and other seasonal products may
only have to satisfy the requirements for their specific, limited
exposure.
Appearance
Aesthetic requirements can entail many material and part-design
issues. For example, a need for transparency greatly reduces
the number of potential plastics, especially if the part needs high
clarity. Color may also play an important role. Plastics must often
match the color of other materials used in parts of an assembly.
Some applications require the plastic part to weather at the same
rate as other materials in an assembly.
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In resins, custom colors generally cost more than standard
colors, particularly for small-order quantities. For certain
colors and effects, some parts may need to be painted or
decorated in the mold. Depending upon the application,
parts with metallic finishes may require painting, in-mold
decorating or vacuum metallization. Surface finishes
range from high-gloss to heavy-matte. Photoetching the
mold steel can impart special surface textures for parts.
Styling concerns may dictate the product shape, look, and
feel, especially if the product is part of a component
system or existing product family. Note all cosmetic and
non-cosmetic surfaces. Among other things, these areas
may influence gate, runner, and ejector-pin positioning.
Many part designs must include markings or designs such
as logos,warnings, instructions, and control labels.
In conclusion, when determining the right requirements
for a certain material to be used, always consult the
supplier for the complete material specifications and
it’s characteristics for a certain application. Mold
manufacturers should also be consulted for the
compatibility of a certain material with regards to the
actual manufacturing of toolings for use in injection
process.
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3. PLASTIC MATERIALS
3.3 COMMON THERMOPLASTIC MATERIALS AND TYPICAL WALL THICKNESSES

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4. PART DESIGN GUIDELINES

4.1 Parting Lines

Parting line consideration depends upon shape and the

function of the part. If a shaft diameter is used as a bearing FIGURE 4.1a
surface and is going to be injection molded, it cannot
tolerate a conventional parting line. In this situation,
incorporating small flats on the shaft at the parting line will
avoid mismatch and minimal flash conditions (see Fig. 4.1a)

The parting line depends on the shape of the part. (Figure

4.1b) illustrates an irregular parting line. When
a parting line involves two mating halves with close FIGURE 4.1b
tolerances, the mold mating steel parts should be
interlocked for good positioning or take in an allowance for
possible mismatches. The allowance should be in the
0.005 in to 0.010 in range relative to the finished dimension.

Keep features in the parting plane to simplify the part.

When a stepped parting line is required, allow 7degrees
for shut-off. Minimum shut-off angle is 5degrees. See
(Figure 4.1c) FIGURE 4.1c

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4.2 Wall Thickness

The number one rule for designing plastic parts is uniform

wall thickness. Uniform walls aid in material flow in the
mold, reduce the risk of sink marks, molded-in stresses Figure 4.2a
and differential shrinkage.
For non-uniform walls, the change in thickness should not
exceed 15% of the nominal wall (see Figure 4.2a) and
should transition gradually.
Corners should always be designed with a minimum fillet
radius of 50% of the wall thickness and an outer radius of
150% of the wall thickness to maintain a uniform wall
thickness (see Figure 4.2a).

Consider moldability when selecting the wall thicknesses for

your part. Flow length — the distance from the gate to the
last area fill — must be within acceptable limits for the plastic
resin chosen. Excessively thin walls may develop high molding
stresses, cosmetic problems, and filling problems that could
restrict the processing window. Conversely, overly thick walls
can extend cycle times and create packing problems. Avoid
designs with thin areas surrounded by thick perimeter sections
as they are prone to gas entrapment problems (see Figure 4.2b)

Many designs, especially those converted from cast metal

to plastic, have thick sections that could cause sinks or
voids. When adapting these designs to plastic parts, core
or redesign thick areas to create a more uniform wall
thickness (see Figure 4.2c).
Figure 4.2b Figure 4.2c

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4.3 Draft Angle
Draft — providing angles or tapers on product features such as walls,
ribs, posts, and bosses that lie parallel to the direction of release from
the mold — eases part ejection. Figure 4.3a shows common draft
guidelines. How a specific feature is formed in the mold determines
the type of draft needed. Features formed by blind holes or pockets —
such as most bosses, ribs, and posts — should taper thinner as they
extend into the mold. Surfaces formed by slides may not need draft
if the steel separates from the surface before ejection. Other rules of Figure 4.3a
thumb for designing draft include:

• Draft all surfaces parallel to the direction of steel separation;

• Angle walls and other features that are formed in both mold halves
to facilitate ejection and maintain uniform wall thickness;
• Use the standard one degree of draft plus one additional degree
of draft for every 0.001 inch of texture depth as a rule of thumb; and
• Use a draft angle of at least one-half degree for most materials.
Design permitting, use one degree of draft for easy part ejection.

Less draft increases the chance of damaging the part during ejection.
Additionally, molders may have to apply mold release or special mold
surface coatings or treatments, ultimately leading to longer cycle times
and higher part costs. The mold finish, resin, part geometry, and mold
ejection system determine the amount of draft needed. Generally,
polished mold surfaces require less draft than surfaces with machined
finishes. An exception is thermoplastic polyurethane resin, which tends
to eject easier from frosted mold surfaces. Parts with many cores may
need a higher amount of draft.

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4.4 Ribs
Ribs provide a means to economically augment stiffness
and strength in molded parts without increasing overall
wall thickness. Other uses for ribs include:
• Locating and captivating components of an assembly;
• Providing alignment in mating parts; and
• Acting as stops or guides for mechanisms.

Ribs usually project from the main wall in the

mold-opening direction and are formed in blind
holes in the mold steel. To facilitate part ejection
from the mold, ribs generally require at least
one-half degree of draft per side (see figure 4.3a).
More than one degree of draft per side can lead to (Figure 4.3a)
excessive rib thickness reduction and filling
problems in tall ribs.
Generally, taller ribs provide greater support. To
avoid mold filling, venting, and ejection problems,
standard rules of thumb limit rib height to
approximately three times the rib-base thickness.
Because of the required draft for ejection, the tops (Figure 4.3b)
of tall ribs may become too thin to fill easily. Additionally,
very tall ribs are prone to buckling under load. If you
encounter one of these conditions, consider designing
two or more shorter, thinner ribs to provide the same
support with improved moldability (see figure 4.3b).
Maintain enough space between ribs for adequate mold
cooling: for short ribs allow at least two times the wall
thickness.

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4.5 Bosses screws or threaded
inserts nominal
Bosses are used in many part designs as points for attachment diameter
and assembly. The most common variety consists of cylindrical
projections with holes designed to receive screws, threaded
inserts, or other types of fastening hardware. As a rule of thumb, TYPICAL BOSS DESIGN
the outside diameter of bosses should remain within 2.0 to 2.4 Figure 4.4a
times the outside diameter of the screw or insert. (Figure 4.4a)
radius
To reduce stress concentration and potential breakage, bosses
should have a blended radius, rather than a sharp edge, at their
base. Larger radii minimize stress concentration but increase
the chance of sink or voids. Radii at the base should be 25 to
50% of the nominal wall thickness. (Figure 4.4a)

To limit sink on the surface opposite the boss,

keep the ratio of boss-wall thickness to nominal-
wall thickness the same as the guidelines for rib
thickness (see table 4.4a).
If the boss-wall thickness must
Table 4.4a exceed the recommended ratio,
Rib or Boss thickness as a consider adding a recess around
Percentage of Wall thickness the base of the boss to reduce the
severity of sink. Figure 4.4b
(as shown in figure 4.4b) RECESS

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4. PART DESIGN GUIDELINES
4.5 Bosses
Avoid bosses that merge into sidewalls
because they can form thick sections
that lead to sink. Instead, position the
bosses away from the sidewall, and if
needed, use connecting ribs for support
(see figure 4.4c). Consider using openboss
designs for bosses near a standing
wall (see figure 4.4d).
Figure 4.4c
PLASTIC PART AND MOLD DESIGN GUIDE
Normally, the boss hole should extend to the base-wall level, even if
the full depth is not needed for assembly. Shallower holes can leave
thick sections, resulting in sink or voids. Deeper holes reduce the
base wall thickness, leading to filling problems, knit-lines, or surface
blemishes. The goal is to maintain a uniform thickness in the
attachment wall (see figure 4.4e).
Figure 4.4e
Figure 4.4d
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4.5 Bosses Figure 4.4f

Because of the required draft, tall

bosses — those greater than five times
their outside diameter — can create a
filling problem at their top or a thick
section at their base. Additionally, the
cores in tall bosses can be difficult to
cool and support. Consider coring a tall
boss from two sides or extending tall
gussets to the standoff height rather
than the whole boss (see figure 4.4f).

Other alternatives include splitting

a long boss into two shorter mating
bosses (see figure 4.4g) or repositioning
the boss to a location where it can be
shorter. Figure 4.4g

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4.6 Gussets
Figure 4.6a

Gussets are rib-like features that add support to structures

such as bosses, ribs, and walls (see figure 4.6a ). As with ribs,
limit gusset thickness to one-half to two-thirds the thickness of
the walls to which they are attached if sink is a concern.
Because of their shape and the EDM process for burning
gussets into the mold, gussets are prone to ejection problems.
Specify proper draft and draw polishing to help with mold release.
The location of gussets in the mold steel generally prevents
practical direct venting. Avoid designing gussets that could trap
gasses and cause filling and packing problems. Adjust the shape
or thickness to push gasses out of the gussets and to areas that
are more easily vented (see figure 4.6a ).

gusset

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4.7 Sharp Corners
Sharp inside corners concentrate stresses
from mechanical loading, substantially reducing
mechanical performance. Figure 4.7a shows
the effect of root radius on stress concentration
in a simple, cantilevered snap arm. The stress
concentration factor climbs sharply as the radius-
to-thickness ratio drops below approximately 0.2.
Conversely, large ratios cause thick sections,
leading to sinks or voids.
A radius-to-thickness ratio of approximately 0.15
provides a good compromise between performance
and appearance for most applications subjected to
Light to moderate impact loads.
Figure 4.7a
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Initially use a minimal corner radius when designing parts made
of high-shrinkage materials with low notch sensitivity to prevent
sink and read-through. Inside corner radii can then be increased
as needed based upon prototype testing.
In critical areas, corner radii should appear as a range, rather than a
maximum allowable value, on the product drawings. A maximum value
allows the mold maker to leave corners sharp as machined with less
than a 0.005 inch radius. Avoid universal radius specifications that
round edges needlessly and increase mold cost (see figure 4.7b).
Figure 4.7b
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4.8 Holes and Cores
During mold filling, the advancing plastic flow can exert
very high side forces on tall cores forming deep or long holes.
These forces can push or bend the cores out of position, altering
the molded part. Under severe conditions, this bending can
fatigue the mold steel and break the core.
Generally, the depth-to-diameter ratio for blind holes should not
exceed 3:1. Ratios up to 5:1 are feasible if filling progresses
symmetrically around the unsupported hole core or if the core
is in an area of slow-moving flow. Consider alternative part
designs that avoid the need for long delicate cores, such as the
alternative boss designs in figures 4.4f and 4.4g page 15.
Figure 4.8a Figure 4.8b
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If the core is supported on both ends, the guidelines for length-
to-diameter ratio double: typically 6:1 but up to 10:1 if the filling
around the core is symmetrical. The level of support on the core
ends determines the maximum suggested ratio (see figure 4.8a).
Properly interlocked cores typically resist deflection better than
cores that simply kiss off. Single cores for through-holes can
interlock into the opposite mold half for support.
Mismatch can reduce the size of the opening in holes formed by
mating cores. Design permitting, make one core slightly larger
(see figure 4.8b). Even with some mismatch, the required hole
diameter can be maintained. Tight tolerance holes that cannot be
stepped may require interlocking features on the cores to correct
for minor misalignment. These features add to mold construction
and maintenance costs. On short through-holes that can be
molded with one core, round the edge on just one side of hole to
eliminate a mating core and avoid mismatch (see figure 4.8c).
Figure 4.8c
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4.9 Undercuts Figure 4.9a

Ideally, a plastic part should be designed so that it can be

ejected from the mold without any special mold actions. Special
mold movements such as side action, side coring, angle pins,
collapsible cores and some unscrewing mechanisms should be
avoided if possible. These mold actions can be expensive to tool,
add to mold maintenance, may interfere with the mold’s cooling
layout and may ultimately add to the cycle time of the overall
production. Their use should be limited if possible. As an
example, the hole in the sidewall of the part shown in Figure 4.9a
would require side action to pull the small core pin from the hole
before the part can be released from the cavity as the mold opens.

Clever part design or minor design concessions often can

eliminate complex mechanisms for undercuts. Various
design solutions for this problem are illustrated in figures 4.9b
through 4.9d . Get input from your mold designer early in product
Figure 4.9c core
design to help identify options and reduce mold complexity.

Figure 4.9b
part

cavity
Figure 4.9d

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Figure 4.9e
4.9 Undercuts

For some complex parts the ideal will not exist and mechanical STRIPPER
movement of one type or another will be required. A description PLATE
of possible movements includes the following:

a. Deflection – dependent on the material and the amount of the

undercut it may be possible to deflect the part out
of the mold. See Figure 4.9e

b. Inserts - the use of removable inserts that eject with the part
is an option, certainly for prototype tooling. The
disadvantages are the inserts must be removed from INSERTS
the ejected part and repositioned in the mold thus possibly
extending the cycle time. See Figure 4.9f.
Figure 4.9f CAMS or hydraulic/
c. Cams – cams or hydraulic/pneumatic pneumatic cylinders
cylinders move part of the mold
out of the way to permit part
ejection. These will increase the
complexity of the mold making it
more expensive and also mean a
controller is required to operate
them during the molding cycle.
Cycle times will also be affected.
See Figure 4.9f.

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4.9 Undercuts e. Stepped Parting Line
– by repositioning parting line, it may be possible to eliminate
For some complex parts the ideal will not exist
undercut features; although this may add to the complexity
and mechanical movement of one type or another
of the tool, it is the most recommended solution. See Figure 4.9h
will be required. A description of possible movements
includes the following: Figure 4.9h
d. Slides – by means of angled pins and rods mounted
on the mold that may be possible to move
the part of the mold forming the undercut
in the direction of the angled pin during the
opening sequence of the mold. This then
allows ejection of the part. See Figure 4.9g

Angled Pin Slide or Plastic Part

or Rod sliding block Figure 4.9g
Ejector Pin

Mold Close Mold Open(on the way to part ejection) Part Ejection

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4.9 Undercuts
f. Lifters – Shallow undercuts can often be formed
by spring-loaded lifters (see figure 7-
6) or lifter rails attached to the ejector
system. These lifters move with the
part on an angle during mold opening
or ejection until the lifter clears the
undercut in the part.See Figure 4.9j
Figure 4.9j
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g. Collapsible cores
Features such as internal threads,
dimples, slots, or grooves on the
inside of holes or caps may require
collapsible cores. These complex
cores are made in segments that Part Ejection
collapse toward the center as they
retract during mold opening (see
figure 4.9k). Available in a variety
of standard sizes from various
moldcomponent suppliers, these
specialty cores are typically
modified to produce the desired
undercut shape. The number and
complexity of individual core
components limit the minimum size
of collapsible cores. Collapsible
cores are rarely used for inside
diameters less than 0.625 inch.
Figure 4.9k
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4.10 Molded-in Threads

Thread profiles for metal screws often Figure 4.10a Figure 4.10b
have sharp edges and corners that
can reduce the part’s mechanical
performance and create molding Thread
problems in plastic designs. Rounding Relief
the thread’s crests and roots lessens
these effects. Figure 4.10a shows
common thread profiles used in
plastics. Although less common than
the American National (Unified) thread,
Acme and Buttress threads generally
work better in plastic assemblies.
Consider the following when specifying
molded-in threads:

- Use the maximum allowable radius

at the thread’s crest and root.
- Stop threads short of the end to avoid
making thin, feathered threads that can
easily cross-thread. (see figure 4.10b)
- Limit thread pitch to no more than 32
threads per inch for ease of molding
and protection from cross threading.
- Avoid tapered threads unless you can
provide a positive stop that limits hoop
stresses to safe limits for the material.

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Figure 4.10d
4.10 Molded-in Threads
Tapered pipe threads, common in plumbing for fluid-tight connections, are
slightly conical and tapered and can place excessive hoop stresses on the
internal threads of a plastic part. When mating plastic and metal tapered
threads, design the external threads on the plastic component to avoid
hoop stress in plastic or use straight threads and an “O” ring to produce
the seal (see figure 4.10c). Also, assure that any thread dopes or thread
lockers are compatible with your selected plastic resin. Polycarbonate
resins, in particular, are susceptible to chemical attack from many of these
compounds.

Figure 4.10c For best performance, use threads

designed specifically for plastics.
Parts that do not have to mate with
standard metal threads can have
unique threads that meet the specific
application and material
requirements. The medical industry,
for example, has developed special, Figure 4.10e
plastic-thread designs for Luer-lock
tubing connectors (see figure 2-37).
Thread designs can also be simplified
for ease of molding as shown
in figure 2-38.

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4. PART DESIGN GUIDELINES

4.11 Lettering

The molding process adapts easily for

molding-in logos, labels, warnings,
diagrams, and instructions, saving the
expense of stick-on or painted labels,
and enhancing recyclability. Deep,
sharp lettering is prone to cosmetic
problems, such as streaks and tear
drops, particularly when near the gate
To address these cosmetic issues, consider
the following:

- Limit the depth or height of lettering into Figure 4.11a

or out of the part surface to approximately
0.010 inch (0.254mm)

- Angle or round the side walls of the letters

as shown in figure 4.11a.

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5. THERMOPLASTIC PROCESSING METHODS
5.1 Injection Molding
INJECTION MOLDING of thermoplastics is the equivalent of
pressure die casting of metals. Molten polymer is injected
under high pressure into a cold steel mold. The polymer
solidifies under pressure and the molding is then ejected.
Various types of injection molding machines exist, but the
most common in use today is the reciprocating screw machine
(shown schematically). Capital and tooling costs are very high.
Production rate can be high particularly for small moldings.
Multicavity molds are often used. The process is used almost
exclusively for large volume production.
NCR Confidential
PLASTIC PART AND MOLD DESIGN GUIDE
Design guidelines
Complex shapes are possible. Thick sections or large changes
in section are not recommended. Small reentrant angles are possible.
Technical notes
Most thermoplastics can be injection molded. Some high
melting point polymers (e.g. PTFE) are not suitable.
Thermoplastic based composites (short fiber and particulate
filled) are also processed Injection-molded parts are generally
thin-walled.
Typical uses
Extremely varied. Housings, containers, covers, knobs, tool
handles, plumbing fittings, lenses, automotive trims, etc.
The economics
Tooling cost range covers small, simple to large, complex
molds. Production rate depends on complexity of component
and number of mold cavities.
The environment
Thermoplastic sprues can be recycled. Extraction may be
required for volatile fumes. Significant dust exposures may
occur in the formulation of the resins. Thermostatic controller
malfunctions can be extremely hazardous.
27

5. THERMOPLASTIC PROCESSING METHODS
5.2 Polymer Extrusion
In POLYMER EXTRUSION, polymer in powder or granule/pellet form
is processed by a rotating screw through a heating chamber and the
resulting melt is forced through a shaped die orifice. The extrudate
is cooled as it leaves the die. The extrudate is then 'drawn down' to a
smaller crosssection. The process is used to coat wire, which can be
achieved at very high speeds. Extrusion is also used as a preprocess
to many of the molding processes such as injection molding. The
process has the advantage of relatively low tooling costs, though
capital costs are high and the output usually requires further
processing, varying from simply cutting to size to remelting and
injection molding. Die design is complicated by 'die swell', hence
tolerances are not as tight as for the pressure molding processes.
NCR Confidential
PLASTIC PART AND MOLD DESIGN GUIDE
Design guidelines
Limited to uniform prismatic shapes (constant cross-section).
Fairly complex cross-sections are possible including hollow shapes.
Technical notes
Most polymers including particulate and short fiber filled
thermoplastic composites. Most commonly used
for thermoplastics but also used for thermosets, elastomers and
foams with suitable modifications to the process.
Typical uses
Rods, channels, pipes, tubes, window frames, plastic coated wire,
seals, edge guards, filaments, film (film blowing process),
sheet stock, pellet stock (e.g. for IM).
The economics
Tooling cost range covers small, simple to large, complex dies.
The environment
Dust exposure in resin formulation. Thermostatic controller malfunctions can
be extremely hazardous.
28

5. THERMOPLASTIC PROCESSING METHODS
5.3 Thermoforming
THERMOFORMING involves the heating of a thermoplastic sheet to its
softening point followed by forcing it against the contours of a mold
and then cooling. Various thermoforming processes are used including
vacuum forming, pressure forming, plug-assisted forming and drape
forming. All of the processes rely on a pressure differential to force the
sheet against the mold. Female or male molds may be used. The process
is capable of handling a very large range of sizes from items such as
disposable drinks cups to boat hulls. Similarly, the process is capable of
a wide range of production capabilities from low to very high volume.
The process has the following advantages: low tooling costs (low
pressures and one mold half only), low capital costs, high production
rates (automated machinery), and, in addition, it can use predecorated
sheet stock. The process gives good physical properties and quality
(thinning can occur at corners). The disadvantages include: raw material
is more expensive (sheet rather than pellet), sheet trimming required,
and sheet scrap cannot be recycled directly. Also, the process can be
labor intensive.
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PLASTIC PART AND MOLD DESIGN GUIDE
Design guidelines
Shape capability limited to simple shapes of constant cross-section. Undercuts
are possible but increase tooling costs considerably.
Holes and openings are not possible without additional processes.
Fiber reinforcement may further limit formability.
Technical notes
The process is used with thermoplastics, foams and short fiber reinforced
thermoplastics. ABS, PA, PC, PS, PP, PVC, polysulfones,
PBT and PET are particularly suited. Some limitation on fiber content. High
melt viscosity is best Maximum depth-to-width ratios vary from
0.5 to 2 depending on method of forming.
Typical uses
Trays, signs, packaging, refrigerator liners, aerospace components
e.g. large secondary structure air frame parts - helicopter fairings and
cowlings, boat hulls, bath tubs, drinks cups, etc.
The economics
Tooling cost range covers small, simple to large, complex molds.
29

5. THERMOPLASTIC PROCESSING METHODS
5.4 Extrusion Blow Molding
In EXTRUSION BLOW MOLDING, a tube (or parison) is extruded and
clamped in a split mold. Air is then injected under pressure inside
the parison, blowing the polymer against the mold walls where it
cools and freezes. The mold is opened and the part ejected. Surplus
material at both ends of the part is then removed. The process uses
thermoplastics of high melt viscosity and high molecular weight.
It is most widely used with PE (especially HDPE), PP and PVC.
Other thermoplastics are also used. The process is capable of
producing irregular shaped containers and blown handles.
Mold cost is lower than for injection blow molding.
It is generally most competitive for larger containers
(capacity > 0.5 L) and high batch sizes.
NCR Confidential
PLASTIC PART AND MOLD DESIGN GUIDE
Design guidelines
Used for thin-walled hollow or tubular articles with small openings
(e.g. bottles). Irregular shapes are possible.
Technical notes
Thermoplastics commonly used include: HDPE, LDPE, PP, ABS and uPVC.
Limited level of reinforcement possible for composite materials (i.e. particulate
and short fibers) The wall thickness should be as uniform as possible to
ensure more rapid molding cycles and to avoid
distortion.
Typical uses
Primarily bottles and containers - from small bottles to large (10000L)
oil storage tanks. Useful for larger containers and irregular shapes e.g.
detergent bottles, drums, tanks, toys (balls, baseball bats, etc.).
The economics
Tooling cost range covers small, simple to large, complex molds.
The environment
Waste material is recyclable.
30

5. THERMOPLASTIC PROCESSING METHODS
5.5 Injection Blow Molding
In INJECTION BLOW MOLDING, a hollow preform is injection-molded
over a mandrel which provides the hollow shape. The mandrel
transfers the hot preform to the blow molding die and also functions
as the blow nozzle. Air is injected under pressure through the mandrel
blowing the polymer radially against the mold walls where it cools and
freezes. The mold is opened and the part ejected. The process produces
no waste material. Injection blow molding offers better control over
finished part weight and wall thickness (than extrusion blow molding)
and is capable of high tolerances in the unblown, injection-molded neck
area, hence it is useful for screw closures, etc. Handles may be molded
in (solid only). The process is most competitive for production of small
bottle sizes (< 360mL), for rigid thermoplastics (e.g. PS, PC, PET, etc.),
and for wide mouth containers. Tooling costs are much higher than for
extrusion blow molding, hence process is only used for volume
production. Stretch Blow Molding is an important variant. It is most
commonly used for the production of oriented PET drinks bottles.
NCR Confidential
PLASTIC PART AND MOLD DESIGN GUIDE
Design guidelines
Used for thin-walled hollow or tubular articles with small openings
(e.g. bottles). Suitable for fairly regular shapes.
Technical notes
Thermoplastics commonly used include PET, PC, HDPE, LDPE, PP,
ABS and uPVC. Limited level of reinforcement possible for
composite materials (i.e. particulate and short fibers). The wall
thickness should be as uniform as possible to ensure more rapid molding
cycles and to avoid distortion.
Typical uses
Primarily bottles and containers - largely small bottles (< 0.5L), wide mouth
containers, and simple shapes.
The economics
Tooling cost range covers small, simple to large, complex molds.
The environment
Waste material is recyclable. Significant dust exposures may occur
in the formulation of the resins. Thermostatic controller malfunctions can be
extremely hazardous.
31

6. PAINTING, PLATING AND DECORATING
6.1 Painting
While some plastic parts require painting, plating,
and/or decorating for aesthetic or functional concerns,
most do not for two reasons:
first, the injectionmolding process accommodates a
diversity of high-quality surface finishes and textures;
second, thermoplastic resins can be produced in a
rainbow of colors.
Some specific instances where painting or plating may
be needed or required include:
- protecting final assemblies from harsh chemicals or
UV degradation,
- shielding electronic devices from EMI/RFI radiation,
- or adding graphics or labeling in contrasting colors.
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PLASTIC PART AND MOLD DESIGN GUIDE
Most plastics accept paint systems well, especially the
amorphous resins. With special preparation of the surface
for better adhesion (cleaning is essential), even the more
difficult plastics, i.e., PE, PP and Acetal, which have more
slippery surfaces and chemical resistance, can be painted.
Nylon and PET are excellent resins for paint applications,
especially where high-temperature curing is required. Their
ability to tolerate high temperatures for long periods of time
without softening is a key advantage.
Some of the common reasons for painting thermoplastics are:
- To enhance aesthetics and provide uniform color and
texture to assemblies made of different materials or by
different processes.
- They also offer colors or surface effects that resins cannot
such as certain metallic or stippled effects.
- Some perform a function such as being an electrically
conductive paint for EMI/RFI shielding.
- Paints and coatings can also protect the plastic substrate from
chemicals, abrasion, or environmental attack.
- Coatings can also prevent attack from cleaning solvents,
lubricants, and other substances encountered in-use or
during manufacture.
- Commercial scratch resistant coatings commonly provide
abrasion resistance for lenses.
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6. PAINTING, PLATING AND DECORATING

6.1 Painting
Other Design Considerations for Painting
The common types of paints used on plastics include
polyurethane, acrylic, alkyd, epoxy, and vinyl. *In all application methods, parts should be clean and free of surface
contamination for good paint adhesion. When possible, design parts
* Polyurethane paints provide a flexible, durable finish, cure to release from the mold easily, so they can be ejected without using
without heat, and are compatible with most plastics, including external mold release sprays.
many chemically sensitive, amorphous plastics, such as ABS
and polycarbonate blends. *Oils from hands can also contaminate the part surface. Consider
designing designated handling areas or features to reduce
* Epoxies typically produce hard, tough, glossy finishes. contamination in critical painting areas. Part design can have a direct
impact on the ease and cost of painting.
* Vinyls tend to produce soft, rubbery finishes.
*To achieve uniform coverage, avoid undercuts and deep, narrow
* Acrylic paints give brittle, scratch resistant finishes that resist recesses, which may not coat completely. Sharp corners can be
most common oils. difficult to coat sufficiently and may chip or wear through.
*Consider painting transparent parts on the back surface
Paint-Selection Considerations
(or second surface) to protect the paint from scratches and abrasion.
Semi-crystalline plastics, such as nylons, tend to be chemically
resistant to most solvent systems and often require special pre-treatments
*Brittle coatings and paints can greatly reduce the impact performance
or primers. Acetal, polypropylene, and polyethylene,
of painted plastic parts. Cracks in the paint or coating act as stress
which have waxy surfaces, are chemically resistant to most
concentrators to initiate fracture in the plastic substrate. Exercise
solvent systems as well.
extra care in the design and paint selection for painted parts subjected
Amorphous plastics, such as ABS, because they are less chemically
to impact loads. Flexible paint systems, such as twopart urethanes,
resistant, achieve good adhesion with many more paint systems.
tend to perform better in impact applications.
Look for a system that is not too chemically aggressive: especially
for polycarbonate blends. To achieve the optimum match of substrate
and paint system, consult both your resin and paint suppliers before
making your final selection.
The cost of the paint is usually insignificant compared to the labor and
overhead costs, and the cost of complying with environmental
protection regulations. Be sure to consider the cost of the entire
process when making your selection.

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6. PAINTING, PLATING AND DECORATING
6.2 Plating Electroplating
Prior to electroplating, the nonconductive plastic surface of most
plastics must first undergo an electroless chemical process to
deposit a conductive metallic film layer. The electroless process
usually involves immersing the parts in a series of specially
formulated, aqueous baths and rinses to clean, etch, and activate
the part surface. Then, a metallic film layer, such as copper, is
chemically deposited on the part. After this treatment, more
conventional metalplating methods apply additional metal layers
to the now conductive surface. A common plating combination is
nickel over copper. Many electrical-shielding applications skip the
electroless step and apply only an electroless plating layer to the
inside surface of the housing or device (see figure 6.2a).
Figure 6.2a
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PLASTIC PART AND MOLD DESIGN GUIDE
Design Considerations for
Electroplating
The electroplating process places special requirements on the plastic part
design. Because electric current density distribution over the part surfaces
determines plating thickness, high current density at edges, notches, and
outside corners can lead to excessive plating buildup (see figure 6.2b).
Recessed areas plate at lower current densities and tend to plate much
thinner than other areas. To minimize these problems consider the
following:
• Add a radius of at least 0.010 inch (0.254mm)to all plated edges.
• Include a 1/16 inch (1.5875mm)minimum radius on all outside
corners.
• Avoid extreme recesses that could lead to inadequate
plating thickness.
Figure 6.2b
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6. PAINTING, PLATING AND DECORATING

6.2 Plating 6.2.1 Electroplating

Figure 6.2c

During plating, molded parts mounted on specially designed

plating racks pass on conveyors through the various baths
and rinses. These racks both secure and orient the parts for
total immersion and complete draining at each step.
Your part must be stiff enough to resist flexure and distortion
when clamped onto the rack. Otherwise, the thinplated layer
could crack as the parts are removed and handled.
Consider edge-stiffening and surface-crowning to reduce
flexure and cracking (see figures 6.2c and 6.2d).
The points where the rack clamps contact the part will
not plate. Plan for these contact points and work with your
plater to find suitable clamp locations. Other design
considerations include:

• Avoid features that may trap air during immersion

in the baths, or hinder rinsing afterwards. Figure 6.2d

• Design clamping points that secure the part on the

rack without flexing it.

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6. PAINTING, PLATING AND DECORATING
6.2 Plating 6.2.2 Vacuum Metallization
Vacuum Metallization
The vacuum metallizing process
deposits an extremely thin metallic
film (typically 1.5 microns) onto plastic
parts in a vacuum chamber. The process
usually begins with the application of a
specially formulated base coat to
smooth out surface irregularities and
improve metal adhesion. After curing,
the coated parts move to special racks
that rotate within the vacuum chamber
to provide the uniform coverage during
the line-of-sight deposition process.
Deposition takes place by vaporizing
the metal, usually aluminum, and
then condensing it onto the part
surface. Tungsten filaments or
electron beams typically provide the
energy to vaporize the source metal
through direct sublimation from a
solid to a vapor. After metallization,
decorative parts usually receive a
clear topcoat to protect the thin
metal film from abrasion. Metallized
surfaces in protected environments,
such as reflectors in sealed lighting
applications, can often skip the topcoat
step (see figure 6-10).
PLASTIC PART AND MOLD DESIGN GUIDE
A related process, sputter deposition, uses
mechanical displacement, rather than heat, to
vaporize the coating metal. An inert gas plasma
impacts the metal to provide the energy for
phase transition. Sputter deposition offers thicker
metallic layers, and more metal choices than
traditional vacuum metallization. Common
metals and alloys include chromium, copper, gold,
tungsten, stainless steel, and brass. Sputtering also
tends to provide better adhesion and abrasion
performance than conventional vacuum metallization.
Figure 6.2d
NCR Confidential
Design Considerations for Vacuum
Metallization
Because vacuum metallization
processes deposit metal films in a
line-of-sight pattern, deep recesses
and undercuts will not coat. Typically,
the part must rotate for full coverage
of surfaces and standing features.
Areas “shadowed” by other elements
of the part geometry, despite being
rotated, will also not coat. Complete
front-and-back coverage may require
a second racking step to reorient the
parts, and an additional pass through
the metallization process. Vacuum
metallization works best on parts with
relatively simple shapes that require
coating on just one side. The process
is often limited to sizes that will fit in
standard vacuum chambers.
Vacuum metallizing is much less
sensitive to processing and part design
than electroplating. Adherence to
standard plastic part design guidelines
and good molding practices is usually
sufficient to obtain satisfactory results.
36

6. PAINTING, PLATING AND DECORATING
6.2 Plating 6.2.3 EMI / RFI Shielding
EMI/RFI Shielding
With the proliferation of electronic devices such as cell phones
and portable computers, Electromagnetic Interference (EMI)
and Radio Frequency Interference (RFI) become increasingly
Important design considerations. EMI and RFI problems occur
when electromagnetic energy escapes an electrical device
and reaches an unintended device, causing a malfunction or
interference. Untreated plastic parts generally appear
“transparent” to electromagnetic energy, requiring a secondary
shielding process or method when used in electronic enclosures
needing EMI/RFI shielding.
A variety of shielding methods exist, including coatings, sheet-
metal shrouds, adhesive foils, and special conductive
fillers in the molding resin. More often, manufacturers use metallic
coating. Each of the metallic-coating processes covered in this
chapter thus far — painting (conductive coatings),
electroless plating, electroplating, and vacuum metallization —
find use in EMI/RFI shielding. A number of factors determine
the best process for your application, such as part geometry and
size, masking requirements, production levels, and required
shielding
performance.
NCR Confidential
PLASTIC PART AND MOLD DESIGN GUIDE
Design Considerations for EMI/RFI Shielding
Enclosure design usually affects shielding performance more than the
coating process chosen. Any openings in the enclosure assembly,
whether they be intentional — holes and cooling vents —
or unintentional — gaps along mating edges, can allow electromagnetic
radiation to escape. The length of the opening determines the frequency
of radiation that can escape. Long gaps, such as between mating halves, could
release a wide range of frequencies. For proper shielding, these interfaces
require a generous overlap and snug fit.
One design employs contact fingers with a slight interference fit to create
a low-impedance connection and reduced gap size. The finger spacing
determines the slot length and the minimum frequency that can escape.
Consult your shielding experts for help in calculating the correct spacing
for your application. Generally, do not place “noisy” circuit boards close
to cooling vents and other possible weak links in the shield.
Part designers and shielding experts need to work together early in the
design process to assure a good combination of performance and
manufacturability .
37

6. PAINTING, PLATING AND DECORATING
6.3 Decorating/Printing Printing/Decorating is often used to apply designs, characters, and
markings to parts.
6.3.1 PAD PRINTING
Pad printing involves pressing ink onto
the part from a custom-designed soft
ink pad. In one process, the patterned
ink pad picks up a film layer deposited
onto a transfer plate by a roller. In
another process, a smooth pad picks up
a pattern of ink from an etched plate
that was flooded with ink and then
wiped with a blade, leaving ink in the
etched recesses of the pattern. In both
processes, the loaded ink pad then
stamps the pattern onto the plastic part.
The soft pad can accommodate textures
and many irregular shapes. Irregular
shapes cause distortions in the printed
pattern that must be compensated by
adjustments in the ink pad pattern.
PLASTIC PART AND MOLD DESIGN GUIDE
6.3.2 SCREENING
Screening, an inexpensive technique
used to decorate flat or cylindrical
plastic parts (see figure 6.3.2 ), begins
with an open-weave fabric or screen,
commonly made of silk, polyester, or
stainless steel, which has been stretched
in a frame. Stencils, often made using
a photoetching process, are then placed
on the screen where ink transfer is
not desired. A rubber squeegee forces
ink through the screen and onto the
part surface. The screening process
requires careful control of the ink
viscosity and ambient conditions to
avoid fluctuations in temperature and
humidity that could cause the screen to
stretch or shrink. Screens also require
periodic cleaning to remove dried ink
that could clog screen.
FIG. 6.3.2
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6. PAINTING, PLATING AND DECORATING

6.3 Decorating/Printing 6.3.4 HOT STAMPING
Hot stamping provides a quick and easy method
for creating colored indentations for numbers,
letters, and demarcations. In this process, a
6.3.3 LASER PRINTING heated stamp presses against a color foil
positioned on the part surface. The force and heat
Laser printing produces designs and simultaneously melt a recess and transfer ink
symbols in plastic parts either by direct from the foil (see figure 6.3.4A). Dome printing, a
marking of the plastic or by selective variation of the hotstamping process, prints on top
evaporation of a coating applied to of raised features or patterns in the molded part
the plastic. In direct laser printing, the (see figure 6.3.4B). The reinforced silicone
laser usually burns dark symbols into rubber pad used in this process compensates for
FIG. 6.3.3 minor deviations in the part surface.
light colored parts (see figure 6.3.3).
Some dark-colored plastics have been
developed that produce light-colored
symbols during laser printing. This FIG. 6.3.4B
process usually does not produce
suitable results for back lighting.
White, back-lit symbols can be
produced on a dark background by first
coating white plastic with an opaque
dark paint. The laser then vaporizes the
paint in the shape of the symbol, and
exposes the white plastic substrate. The
pigmented, white plastic reflects the
laser beam without marking.

FIG. 6.3.4A

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6. PAINTING, PLATING AND DECORATING

6.3 Decorating/Printing

6.3.5 LABELS AND DECALS

Self-adhering printed labels and

decals provide an easy means for
applying items such as logos, model
identification, and decorative graphics.
Available in transparent, opaque,
metallic, or embossed materials, they
offer an unlimited choice of shapes and
colors. Opaque labels are particularly
helpful for hiding trimmed sprue gates.
Instead of relying upon a self-adhering
backing, heat-transfer labeling uses a
heated platen to release the print from
a carrier and attach it to the plastic
part. Labels and decals occasionally
have problems with adhesion. Carefully
pretest and evaluate any proposed
adhesive system on actual production
parts. Also, avoid placing decals and
labels on irregular surfaces, as they will
lift more easily.

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7. DESIGN FOR ASSEMBLY

7.1 Part Consolidation

To lessen the need for fastening

hardware and reduce the number
of assembly operations, consider
consolidating the number of parts
in a given design. Closely scrutinize
your total design for opportunities to
combine function and reduce final
assembly count. By way of example,
figure 7.1 shows several options for
attaching a gear to a shaft: a threepiece
design, featuring a shaft, gear,
and roll pin; a two-piece, snap-on
gear design; and a one-piece shaft and
gear design that needs no assembly.
A variety of factors — including
required strength, wear properties, and
moldability — determine which of these
design options is most feasible.

FIG. 7.1

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7. DESIGN FOR ASSEMBLY

FIG. 7.2a
7.2 Mechanical Fasteners

Mechanical fasteners — screws,

bolts, rivets, and others — and their
installation often represent a large
portion of total assembly costs. They
also add to the cost of dismantling
products for repair or recycling.
To reduce costs, consider replacing
mechanical fasteners with snap-fit
joints, molded-in hinges, latches, and
other similar design features. Use
interlocking and/or nesting features to
reduce the number of screws needed.
When you must use fasteners, choose
from the multitude of inexpensive,
off-the-shelf varieties to lower costs.
Avoid expensive, custom, or low-production
fasteners, unless the performance
advantage justifies the additional
costs. Whenever possible, standardize
fasteners to simplify inventory control
and automation processes, as well as
reduce unit cost. See Fig. 7.2a

Consider simplifying installation. For

example, use hex holes to captivate
nuts during assembly (see figure 7.2b).
FIG. 7.2b

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7. DESIGN FOR ASSEMBLY

7.3 Snap Fit Joints

SNAP-FIT JOINTS
Both economical and versatile,
snap joints can eliminate fastening
hardware, as well as reduce assembly
and disassembly costs in a wide range
of applications. Although they vary
in appearance, all snap-fit joints rely
upon the brief deflection of a flexible
member to interlock a depression
or undercut with a protrusion on a
mating part. Varieties include cantilever FIG. 7.3a
snap-arms, and torsional or annular
snap-joint styles (see figure 7.3a). The
shape of the undercut determines if the
joint can be separated later. Snap-fit
designs with an angled undercut
contact can be disassembled without
first deflecting the snap feature to
disengage the connection.

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7. DESIGN FOR ASSEMBLY

7.3 Snap Fit Joints FIG. 7.3b

Snap-fit joints provide both secure
If designed properly, snap-fit joints attachment and easy disconnection
can secure parts of assemblies, such of electrical connectors. They also
as solenoids and switches, replacing facilitate quick and easy detachment
more expensive screws (see figure 7.3b). of electrical components for repair
Special snap-joint designs can also act and recycling. Some rules of thumb
as latches for access doors and panels. for designing snap-fit joints include:
Multiple snap arms or a combination of
snap arms and rigid undercuts can often
secure covers and panels (see figure • Design parts so that the flexure
4-7). Rounded lids — such as on film during snapping does not exceed
canisters or food-storage containers—use the allowable strain limit of the
annular snap-fit designs for continuous material;
attachment and a good seal. • Design parts so that the flexing
member of the snap-fit joint
returns to a relaxed, undeflected
position after assembly;
• Avoid sharp corners in high-stress
areas, such as at the base of a
cantilever arm;
• Round corners to a minimum
radius of 0.015 inch to reduce
stress concentrations; and
• Avoid excessively large radii that
could lead to sinks or voids.

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7. DESIGN FOR ASSEMBLY

7.3 Snap Fit Joints FIG. 7.3c

Consider molding issues early in part
design. To lower mold-construction
and maintenance costs, design simple, FIG. 7.3d
straight-draw, snap-fit joints (see
figure 7.3c), rather than ones that need
slides in the mold. In some designs, the
proximity of the snap-fit joint to other
part or mold features does not leave
enough room for a slide mechanism.
Annular designs can be particularly
difficult to mold. Some need collapsible
cores or ejector sleeves, which can be
problematic and difficult to maintain.
Consult an experienced mold engineer
before specifying any design that uses
slides or other mechanisms to clear or
eject undercuts. The molding process offers the
versatility to customize snap-fit designs
for each application. For example,
snap arms on frequently used doors
or access panels could have finger
tabs added for easier opening (see
figure 7.3d). Limited-access doors
could have hidden snap-fit joints or
require special tools. Some
applications may require modifications
in the snap arm to prevent excessive
material strain during deflection.

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7.3 Snap Fit Joints

Short Cantilever Design

The conventional cantilever formulas used FIG. 7.3e
in analyzing snap-fit deflections predict a
much smaller deflection than observed in
the field for short cantilevers. The wall from
which the snap protrudes is assumed to be
rigid in the conventional formulas. This is a
valid assumption for long cantilevers, but
not short cantilevers. The intersecting wall
actually deforms under load for short beams.
BASF has proven this both experimentally
and by Finite Element Analysis. The results
of this study were compiled and are shown
in Figure 7.3f for various configurations
(see Figure 7.3e). An example illustrates the
procedure for designing a snap-fit. Formulas
for calculating maximum strain, deflection
and amount of force required to assemble
the parts are also given. A special snap-fit
manual with more detail is available.

FIG. 7.3f

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7.3 Snap Fit Joints (Sample calculations)

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7.4 Press Fit Assembly
FIG. 7.4a
Two parts can be assembled by press-fitting
them together (see Figure 7.4a). Although
this is a common assembly method in
metals, a good design is more critical for
thermoplastics. Since plastics creep (or
stress relax), the designer must allow for a
large reduction of the initial press-fit clamp
force. A good design will minimize the
strain on the plastic (see Figures 7.4b &
7.4c), take tolerance stack-up into account
and estimate the final residual clamp force
due to plastic creep relaxation.
PLASTIC PART AND MOLD DESIGN GUIDE
Press Fit with 2 identical materials Press Fit a Metal Shaft into a Plastic Hub
NOTE: NOTE:
1. Radial deformation, δ, must be doubled 1. Radial deformation, δ, must be
for the total interference fit doubled for the total interference fit
on a diameter. on a diameter.
2. a, b and c are radii, not diameters. 2. b and c are radii, not diameters.
3. Formula is only valid when the shaft and 3. Formula assumes zero
hub are the same material. deformation of the metal shaft.
4. Creep must be fully analyzed. 4. Creep must be fully analyzed.
EXAMPLE:
GIVEN: A metal insert (O.D. = 0.50in) is
to be press-fit into a Ultramid 8233 boss
(O.D. = 0.75in). Determine the maximum
interference of the assembly using a 2%
allowable strain for Ultramid 8233.
*Therefore, the Capron® 8233 boss I.D. should
be designed with an .011in (2δ) maximum interference
(.489in minimum diameter).
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7.5 Adhesive Bonding

FIG. 7.5a
Another method for assembling parts is by applying
an adhesive. Two similar or dissimilar materials can be
assembled together in a strong leak-tight bond. Various
joint designs are shown in Figure 7.5a.
The choice of the adhesive depends on the application
and its end-use environment. Details of some adhesives,
which can be used with BASF Ultramid® and Petra®
products, are highlighted in Table V-1.

Polyurethanes– High strength, good impact resistance,

good low temperature flexibility, two parts (usually), limited
moisture resistance, long cure times, and usually needs to
be fixtured.

Epoxies– High strength, high temperature resistance,

two parts (usually), poor impact resistance, long cure times,
and usually needs to be fixtured.

Cyanoacrylates (example: Krazy Glue•)– High strength,

very fast cure time, one part, limited service temperature
(about 200°F), poor impact resistance, and limited
moisture resistance.

Silicones– Low strength, very high heat resistance, two

parts (usually), good low temperature flexibility, good
impact resistance, good sealing capability, very long cure
times, usually needs to be fixtured, and very high material
cost.

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7.5 Adhesive Bonding

FIG. 7.5a Recommended Adhesives

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Minimizing Stress Relaxation
7.6 Bolts, Nuts and Machine Screws

Standard metal fasteners are also used toassemble

thermoplastic components, although self-tapping
screws are more common. Bolts and screws are used
to join plastic to metal or plastic to plastic. Care must
be taken to prevent excessive compressive stress on
the plastic.
Assembly must be limited to a prescribed torque level
and controlled. Rapid application of torque should be
avoided since most thermoplastics are rate sensitive.
FIG. 7.6b
• High torques generally produce high compressive stress. A rapid initial
stress reduction takes place before leveling off over time. The higher the
stress, the greater the stress relaxation. Elevated temperatures willfurther
increase relaxation.
• A larger head screw or addition of a large diameter metal washer under
the bolt head and/or nut will increase the contact area and reduce stress.
Figure 7.6a illustrates this concept.
• Flat head screws and rivets should be avoided in plastic applications.
These conical shaped fasteners cause a wedging action which results in
high hoop stress and possible failure of the part.
• As stress relaxation occurs, the clamping force and torque retention drop
and the fastener will loosen. A spring washer can be used to maintain
acceptable force and torque levels. Figure 7.6b shows various options to
help counteract stress relaxation. Options 1 & 2 use a shoulder washer or
bolt in combination with the spring washer. The main clamping is metal
to metal while a smaller force holds the plastic.

FIG. 7.6a

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7.7 Self-Tapping Screws
There are two main types of self-tapping fasteners
used In plastic parts: thread cutting and
thread forming. Thread cutting screws are generally
used only on brittle plastics, such as thermosets and
highly filled (+50%) thermoplastics. They cut threads
by means of a slotted shank. Because they actually
remove material when inserted, thread cutting screws
should not be reinstalled and a chip reservoir should
be added. Thread forming screws are generally
preferred for most thermoplastic applications. These
types of screws can be reinstalled a limited number
of times (3-7). For repeated assembly and
disassembly, some form of metal inserts should be
used. There are several styles of thread Forming
screws designed specifically for plastics. Three of
the more widely used are:
Plastite™
These screws have a trilobular cross-section which
roll threads by moving material out of the way as they
are installed. After installation, the material fills back
around the shank lowering the residual stress in the
screw boss.This feature also gives the Plastite• screws
excellent resistance to loosening due to vibration.
Higher hoop stress is produced with these screws.
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PLASTIC PART AND MOLD DESIGN GUIDE
FIG. 7.6b Hi-Lo™
These screws feature a dual lead with a high
thread having a 30°included angle and the low
thread having a 60°angle. These screws have a
high strip torque to drive torque ratio which is
important for small sizes. Lower hoop stress is
produced but higher stress concentrations result
due to acute angle threads.
PT™
This thread design has a single 30°included
angle which reduces hoop stress in the boss
and also provides a high strip torque to drive
torque ratio.
Guidelines for self-tapping fasteners:
1. Thread engagement length should be 2.5 times the screw diameter.
2. Boss diameter should be at least 2 times the pilot hole diameter.
3. Pilot hole diameter should be based on 50%-70% thread engagement.
This can vary with the material and the type of fastener (check with your
Basf design representative).
4. Cored holes should have 1/4°to 1/2°draft/side.
5. Holes should be counterbored or chamfered to a depth of .020 in. to aid
alignment and reduce the chance of boss cracking.
6. Strip to drive torque ratio should be at least 3:1, but the difference in strip
to drive torque is more important than the ratio.
7. Seating torque should be no more than 2/3 strip torque.
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7.8 Inserts
Inserts of various types are used with plastics.
The most common are threaded metal inserts;
either internally threaded nuts or externally
threaded studs. Threaded metal inserts are
used when the assembly application requires
repeated assembly and disassembly or
the assembly needs to resist creep and
compressive relaxation. There are several
methods of installing inserts:
Ultrasonic
This method uses the same equipment as
ultrasonic welding. The high frequency horn
vibrations cause frictional heat between the
insert and plastic, thereby melting it into the
boss. This process takes under 5 seconds
and features low residual stress and
excellent pullout strengths.
PLASTIC PART AND MOLD DESIGN GUIDE
FIG. 7.8a Thermal
This is similar to ultrasonics in that the insert
is melted into the boss but the insert is
heated by a device like a soldering iron. This
method is relatively slow and also yields a
low stress assembly with good pull out
strengths.
Self-tapping
These inserts have an external self-tapping
screw thread and are driven into the hole
using low cost equipment.
Press-fit and Expansion
This type of insertion is not normally desirable.
The insert is pressed in with an interference fit.
The expansion insert is designed to expand
into the side walls of the boss with a tool. Both
methods impart a high stress to the boss, and
they have lower mechanical performance.
Molded-in
This method is often used for large or special inserts. As the name implies,
these inserts are placed in the mold cavity and the plastic is injected,
thereby encapsulating them. The need to place the insert in the mold
increases cycle time and mold damage can occur.
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7.9 Ultrasonic Welding

Ultrasonic welding is a quick and reliable way to
Assemble the same or very similar thermoplastic parts.
Electrical energy is converted into mechanical vibrations
causing frictional heat between mating parts, thereby
melting the plastic. The parts are held in a fixture under
pressure while the ultrasonic energy is applied. The
energy is then shut off and the pressure maintained until
the weld surface has solidified. Total weld time is FIG. 7.9a
generally around 0.5-1.0 second. Standard welder
frequencies are 20 kHz, although 40 kHz units are
In a shear joint, a small contact area is initially
available for small delicate parts.
melted and then continues down the weld
surface as one part is forced into the other. Due FIG. 7.9b
The major factor determining the quality of an ultrasonic
to the good material mixing between the welded
weld is the joint design. The two major types of joint
parts, strong structural and hermetic seals can
designs are shear joints and energy director joints. The
be obtained. Typical joint designs and
choice depends on the type of material to be welded
interference guidelines are shown in Figure 7.9
and the end use requirements.
(a–c). As with energy director joints, flash traps
can be included in the joint design.
Shear Joint
A shear joint is more commonly used on semi-
crystalline materials such as nylon* and polyester. FIG. 7.9c
Due to their sharp melting points, semi-crystalline
resins often do not achieve strong welds with
energy director joints. The molten material flowing
from the weld area quickly resolidifies before
welding to the opposite interface.

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7.9 Ultrasonic Welding FIG. 7.9d

FIG. 7.9e
Energy Director
An energy director is a raised triangular
bead molded on one of the joint surfaces.
It concentrates ultrasonic energy causing a
rapid initiation of the melt and welding of
the material. Energy director joints are
normally used for amorphous materials.
Typical joint designs are shown below in
Figure 7.9d. For appearance parts, flash
traps can be designed into the joint.
(Figure 7.9e.)

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7.10 Thermoplastic Staking

Thermal staking is an assembly method

that uses the controlled melting and
reforming of a plastic stud or boss to capture
or lock another plastic or metal component
of an assembly in place.
The plastic stud protrudes through a hole
in the component to be locked in place.
The heated thermal tip contacts the top of
the stud, which melts and fills the volume
of the tip cavity to produce a head, locking
the component in place. The progressive
melting of plastic under continuous pressure
forms the head. When staking, the
right combination of heat and pressure for
the application is critical

FIG. 7.10b

FIG. 7.10a

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7.11 Electromagnetic Welding

Electromagnetic Welding
Electromagnetic welding provides a simple,
rapid and reliable assembly technique to
produce a strong and hermetic joint. A
specially designed strand is placed between
the two parts to be welded. This assembly is
then exposed to an induction heat field which
melts the strand and plastic to form a strong
bond at the interface.
Our studies show the shear strength of the
weld to be about 5000 psi. A variety of joints
can be used as in other welding techniques. A
tongue and groove joint is shown in
Figure 7.11.

FIG. 7.11

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