`

PLASTIC PART DESIGN GUIDELINES

. SPECIFIC FOR AUTOMOTIVE
COMPONENTS
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Plastic Part Design Guidelines Specific for

Automotive Injection Molding Components
Introduction Basic Considerations

• Nominal Wall
• Ribs
• Undercuts
• Holes
• Bosses
• Flanges
• Parting Line
• Gating
• Living Hinge
• Weld/Meld/Knit Lines
• Graining
•  Thick/Thin Transitions
• Basic Tooling Considerations
• Design/Tooling Aides

Basic Considerations

When designing plastic components for the automotive, there are

many things that need to be considered to ensure a part that is both
functional and manufacturable. The following is a basic guideline
that can be utilized, but some rules can be cheated if needed. All
the guidelines are effected by the following three general areas

Part application, Process, and Material

Part application, for automotive, can be broken into two primary

categories - non-structural (decorative trim) and structural (there
may be overlap between the two). The non-structural applications
need
need to be moremore conc
concer
erne
ned
d on the
the aest
aesthe
heti
tics
cs of the
the clas
class
s 'A'
'A'
surface. Examples of these parts are side shields, seat
backs(
backs(exp
expose
osed),
d), door
door trim,
trim, A/B/C
A/B/C pillar
pillar trim,
trim, and I/P (instr
(instrume
ument nt
pane
panels
ls)) cove
covers
rs to nam
name a few.
few. An
Anyt
ythi
hing
ng that
that is visi
visibl
ble
e to the
the
consumer. The structural parts are generally covered or out of view
of the consumer, and the strength or performance of the parts are
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Process of how the parts are made will also contain some limitations
or concerns that need to be considered when designing parts. The
two main processes that Johnson Control use to make auto parts are
injection and blow molding. Blow molding is limited to actions in the
tool that would be used to create side holes or undercut features
that can be done in injection molding. Injection molding is generally
restrictive
restrictive (not including special
special processes
processes)) in the cross-sec
cross-section
tional
al
size of the part, while blow molding allows for channels in the part
that increases strength. This guideline will concentrate on injection
molded parts.

Material used will also affect the guidelines and consultation with
the material supplier is very useful. Highly filled materials will allow
variations in some rules as will unfilled in others. Generally, when a
material is chosen for an application, cost and properties are the
two major factors that will be used to decide.

1 Nominal Wall

1.1 Importance

Nominal wall is the term used to describe the 'main' body of the
part. The consisten
consistency
cy of the nominal
nominal wall is very
very important
important in the
processing and function of the part. Throughout this design guide,
the nomina
nominall wall
wall will
will be refere
reference
nced
d freque
frequentl
ntly
y to define
define proper
proper
ratios when adding attachments. Below is a general cross section of 
a side shield showing the nominal wall and some features added to
it.
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1.2 Flow/Filling

A consistent nominal wall in injection molding will aide in processing

the part better. Melted plastic flows in 'path of least resistance' and
if there are varied thicknesses of the nominal wall, flow of plastic
will be through the thicker sections first. This may cause surface
defects, trapped gas, voids, or pressure drop variations that make
processing difficult. Average nominal wall thickness for decorative
trim components is 2.5 mm, while structural components are 3.0
mm. Filled materials are limited to how thin the nominal wall can go
and consultation with the material supplier is suggested. Below are
examples of nominal wall designs.

1.3 Strength

Proper 'packing' of the part is more difficult if the nominal wall is

varying. This could leave voids or higher stresses in sections of the
part that could affect the performance.

1.4 Warpage

Different nominal wall thickness will have different cooling rates and
different degrees of orientation of polymer chains. This can cause
excessive warpage when part comes out of the tool.
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1.5 Processing

Processing of plastic components are based on cooling time in the

mold. The thicker the wall the longer it takes to cool to a point
where the part can be ejected or taken out of the mold. If a part has
varying wall thickness, the cycle time will be based on the thicker
section. A consistent nominal wall is better for controlling the cycle
time and costs of the parts.

1.6 Exceptions

 There are always exceptions to the rules and this is not different for
nominal
nominal wall applicatio
applications.
ns. Sometime
Sometimes s the design
design requires
requires thicker
thicker
sections (i.e. a heavy boss is required and the nominal wall needs to
be thicker to prevent a sink), but you do not want to make the
whole part thicker and waste material or time. Transition from a
thicker to thin section should be utilized. If the thicker section is
really excessive, a re-evaluation of the design is warranted.

2 Ribs

2.1 Uses

Ribs are used to provide

1) Stiffness to a part
2) Strength to a part
3) Stability to a part (warpage)
4) Method of attachment
5) Method of positioning part in assembly
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non-uniform shrinkage. It must also be remembered that Ribs are

difficult to

• Fill
• Vent
• Eject

2.2 Nominal wall ratio

When designing ribs into a part, you have to be careful about sink
marks caused by too large a rib. General rule of thumb is that the
nominal wall to rib ratio, (class 'A' surfaces) should be designed at
50%.
50%. This
This is mate
materirial
al depe
dependnden
entt some
some mate
materi
rial
als
s may
may allo
alloww a
greater
greater or lesser
lesser ratio.
ratio. Filled materials
materials tend to allow
allow for larger ribs,
than unfilled. If the part is structural and hidden, the wall to rib ratio
can be more.
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2.3 Directional

Be careful when determining rib direction in the part. If ribs are 90

degrees to material flow, part may exhibit a blush or highlight over
top
top of ribs
ribs.. To dimi
dimini
nish
sh chan
chance
ce of rib
rib read
readou
out,
t, ribs
ribs shshou
ould
ld be
designed near edges of part where possible.

2.4 Draft and Depth

Ribs should have draft angles of 1 - 1.5 degrees average. You should
not have any draft less than 0.5 degrees. This would make it very
difficult to mold the part.

 The deeper the rib, the thinner it will be at the end and the harder it
will
will be to fill
fill the
the rib dur
during
ing pro
proces
cessing
sing.. This
his coul
could
d resul
esultt in
incomplete fill of ribs and may defeat purpose. Average rib length is
generally 2.5 - 3.0 x wall thickness, but part may dictate other.
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2.6 Tooling Considerations

Ribs are usually burned into the tool. This leaves a rough finish that
needs to be benched or smoothed out. The deeper the ribs, the
more difficult it is for the tooler to bench the part. You also have to
be aware of placement of rib in part is it in die direction (direction
tool opens and closes) or along an edge. In die direction, ribs are
easier to tool (no special tooling). If the ribs are not in die direction,
they will require a slide or lifter added to the tool. This will add cost
and timing to a tool.

2.7 Design Examples

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3 Undercuts

3.0 Uses

Underc
Undercuts
uts are used
used freque
frequentl
ntly
y in design
designing
ing parts
parts for autom
automoti
otive
ve
com
compone
ponent
nt.. The
The more
ore comm
commonon type
types
s are
are sn
snap
ap fit
fit desi
design
gns
s or
attachment features.

Injection Molding - Types of Undercuts

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inch undercut, you need at least 1 5/8 inch area in front of the
undercut, free of any obstruction or change in contour, for the lifter.

3.2 Design Examples

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4 Holes

4.1 Uses

Holes are used when clearance is needed. Holes are predominantly

useful when a mechanical fastener is used to attach the part to
another. Below is a front side shield with several holes.
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on a side flange or 90 degrees to line of draw, then a slide or lifter is

required. Below is an example of a side shield and how holes were
made.
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 The main use for bosses on a part is for attachment of another part.
 The boss supplies a place for a screw, press fit or snap fit to be put.
Bosses should be treated as round connected ribs when thinking of 
draft, nominal wall ratio, join radius, and depth. The same rules
apply to bosses. Bosses, however, need to be correctly designed to
take the attachment method and stresses associated.

5.2 Designing

When designing bosses, there are two opposing considerations. You

need to make the boss thin enough so that the part surface will not
have a sink mark, yet you also need to make the boss thick enough
to take the stresses associated with screwing a mechanical fastener
or press fitting another part into it. The walls also have to be thick
enough to allow the screw flights to grab and not pull out to easily.
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6.2 Draft Angle

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7 Parting Line

7.1 Location

A parting line is a visible line on the part that is caused by the two
halv
halves
es of a mold
mold meet
meetining
g up.
up. The
The line
line will
will gene
genera
rall
lly
y follo
follow
w the
the
bottom of any side flanges (walls). Every part will be different and if 
there is a concern, discussion with the tooter or molder should take
place.
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7.3 Secondary Actions

When a part design has features that require a secondary action

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As mentioned in the flange, when a part is beaded, the parting line

will be between the wall and the tangent of the radius.
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8.1.2 Sub-gate

A su
sub-
b-ga
gate
te,, as sh
show
own n belo
below,
w, inje
inject
cts
s the
the mate
materirial
al into
into the
the part
part
through a tunnel shaped gate. This type of gate requires a little
more tool work, but the part is self de-gating as it ejects from the
tool. This means that the gate breaks off from the part during the
actual molding cycle and eliminates any extra operation or fixtures.
 This type of gate will also leave a witness
witness mark at location of gate.
gate.
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8.2 Location

 The location of the gate can, technically, be anywhere on the part,

but certain considerations need to be taken.

 The ability to fill the part - flow length of material

material

 The ability to pack out part - warpage

warpage of part

Aesthetics of part - will gate mark be visible and objectionable

 The first two concerns will depend upon the shape and thickness of 
the part as well as the type of material being injected. The answers
to this can be determined with help from the mold source and/or
computer aided help (mold flow, discussed later).

8.3 Gate size

Gate size is very important for the following

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10 Weld/Meld/Knit Lines

10.1 What are they?

Weld/Meld/Knit lines are all terms describing the effect of two or

more flow fronts of material joining or meeting together in the part.
 The example below shows a part and a nd depicts where knit lines would
be.
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of 0.005". The minimum draft angle required would be 1 degree + 5

* 1 degree for grain = 6 degrees.
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12 Thick/Thin Transitions

12.1 Uses

 Thick/thin transitions are generally used to locally thicken an area of 

a part
part to elim
elimin
inat
ate
e a sink
sink mark
mark or add
add stre
streng
ngth
th.. The
The tran
transi
siti
tion
on
should be very gradual.
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13 Basic Tooling Considerations

When designing automotive components, it is good to keep 'n mind

that process of how the parts will be made. This will generally limit
what features can be made in the tool and ultimately molded in
production. If this is kept in mind and resources such as the tool
builder and manufacturer are utilized, parts will be better designed
for all facets - customer performance
performance and appearance requirements,
tool simplicity, and moldability of a quality product. It is also wise to
draw from the expertise of these resources for they generally have