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 Plastic Part Design 2014

Plastic Part Design Thumb Rules

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 Plastic Part Design 2014

Coring out :
Coring out is removal of material
from thick sections of part hence
maintaining uniform wall thickness
and avoiding defects.
 Coring out helps to
maintain uniform wall
thickness.
 Leads to lesser usage of
material.
 Often stronger design by
increasing rigidity.
 Lesser cost.
 Avoids sink mark and
voids.
 The dimension for coring
implies same as
what is given for ribs.

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 Plastic Part Design 2014

Parting line :

Undercuts :

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Example of undercut :

Ribs :

Rib Function:
 Usually used for improving
part stiffness.
 Generally preferable to
add ribs to improve
stiffness rather than
increasing wall thickness
Design Considerations
 Rib Thickness to Wall Ratio
 Height Limits
 Fillets
 Draft
Resulting geometry is a trade off
between molding feasibility and
For cosmetic applications, recommend biasing stiffness
towards “lower sink” dimensions

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 Plastic Part Design 2014

Boss :

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 Plastic Part Design 2014

Gussets :

 The height of the gusset can be up to

95% of the height of the
boss or rib it is attached to
 Depending on the height of the rib
being supported gussets may
be more than 4 times the nominal wall
thickness.
 Gusset base length is typically twice
the nominal wall thickness.
 Limit gusset thickness to one half to
two-thirds the thickness
of the walls to which they are attached if
sink is a concern.
 Specify proper draft and draw
polishing to help with mold
release.
 Avoid designing gussets that could
trap gasses and cause filling
and packing problems.

Example of Gussets :

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 Plastic Part Design 2014

Dog House :
 Dog house is used for mounting
the plastic
part on BIW panel with the help of
Christmas clip.
 Dog house designs accommodate
longer
reaches from plastic “A” surface to
metal structure in addition to providing
retention features for separate piece
fasteners.
 Dog house attachment is generally
supplemented with mechanical fasteners
for appropriate holding strength and
retention
Advantages :
 The dog house is utilized during
the JIT
plant assembly process as a
preliminary locator to “hang” the part prior
to engaging supplemental mechanical
fasteners.

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 Plastic Part Design 2014

Vehicle interior system

Head
Liner(Over
head System)

Instrument
Panel(IP)

Centre
Console(CC)
Seating System
Door Trims

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 Plastic Part Design 2014

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 Plastic Part Design 2014

Cylindrical snap fit :

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 Plastic Part Design 2014

Heat Stake :
Types of Heat Stake
 Staking is a process suited to
connect parts made
from dissimilar materials e.g. plastic to
metal
 One part is provided with studs or
bosses which
protrude through the holes in the other
part. The
stud or the boss is then deformed by
melting the
plastic to form ahead which
mechanically locks the
two parts together.
 Quick and economical.
 No consumables like rivets and
screws required.
 Applicable to thermoplastic
materials including
glass-filled materials.
 The quality of the joint depends on
processing
parameters like
 Temperature of the material
 Pressure applied
 Time

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 Plastic Part Design 2014
Heat Stake :
 High frequency vibrations from a specially
contoured horn, melt the top of a
thermoplastic stud which protrudes through
a hole in the mating part of the assembly.
 Mating material can be a dissimilar plastic
or even metal. When the top of the stud
melts, it forms a head that locks the two
components together.
 The base of the stud must be rounded to
help reduce stress concentration.
 The through hole on the mating part
should
be a close fit to prevent melt from flowing
into the gap between the stud and the
mating part.

Ultrasonic Spot Welding :

 No preformed holes or energy directors,
ultrasonic spot welding joins two layers of
thermoplastic resins with similar melting
temperatures in a single location, forming a
permanent bond.
 The pilot tip melts through the first
surface.
As the tip penetrates the second or bottom
surface, displaced molten plastic flows
between the two surfaces, forming a bond.

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 Plastic Part Design 2014

This is property of CADSYS (CAD

SYSTEM) and is meant only for internal
circulation.
This particular version is draft version.
This is not for printing or circulation.

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