How to Design Custom Plastic Parts That Perform Under Pressure

16 Jan How to Design Custom Plastic Parts That Perform Under Pressure

When plastic parts fail, it can be traced back to fundamental mistakes made at the design level. Without a full understanding of the pressure the part will face in the real world, it’s difficult to design a component that will meet your needs. That’s why we’ve created this guide. Below, you’ll learn what to consider when designing custom plastic parts. By the end, you’ll understand how to create parts that are built to last.

Understand the Type of Pressure Your Custom Plastic Parts Will Face

As mentioned above, it is impossible to design the right part without understanding the pressures it will face. Before beginning the design process, ask yourself the following questions:

• Will the part experience continuous or intermittent load?
• Is pressure static, dynamic, or impact-based?
• Are temperature extremes involved?
• Will the part be exposed to chemicals, moisture, UV, or abrasion?
• How long is the expected service life?

All these questions can help you narrow in on what your part actually needs. For example, a part used in medical device enclosures faces very different stresses than one used in industrial machinery or fluid handling systems. Understanding this can help you reduce costly redesigns later.

Choose the Right Material

Different types of plastics will respond differently to stress, heat, and time. A great custom plastic parts manufacturer will match you with the right material. Common options include polypropylene (PP), polyethylene (PE), ABS, nylon, and polycarbonate.

• Polypropylene (PP): This thermoplastic has excellent chemical, heat, and moisture resistance. It also has high fatigue strength and great impact strength.

• Polyethylene (PE): Like polypropylene, polyethylene has great chemical and moisture resistance. It also stands out with great durability and flexibility.

• ABS: This material is known for excellent impact resistance, good heat stability, and ease of processing. However, it can suffer from poor UV/weathering resistance.

• Nylon: With excellent strength, durability, and wear resistance, nylon is a highly desirable material for a range of applications.
• Polycarbonate: This material offers great impact strength and heat resistance, along with rigidity.

Design Geometry to Distribute Stress Evenly

Strong parts can fail if stress is concentrated in the wrong places. Ideal part geometry can mitigate this problem. Your custom plastic parts manufacturer should add ribs instead of thick walls, reinforce load-bearing areas, account for shrinkage and warping during cooling, and avoid sharp corners.

Prototype and Test Under Real Conditions

Simulation and CAD analysis can only do so much. Physical testing is the best way to determine if your components will work in the real world. Prototyping allows designers to identify weaknesses before full-scale production. Testing might include load and pressure testing, thermal cycling, chemical exposure, and more.

Collaborate Early with a Plastics Manufacturing Partner

The best way to get custom plastic parts that perform under pressure is to collaborate early with a plastics manufacturing partner. At Hudson Valley Plastics, we have decades of experience producing high-quality components across a range of industries. Our team is well-versed in the demands of the cosmetics, pharmaceutical, medical, nutraceutical, automotive, and packaging industries. We pride ourselves on competitive pricing and exceptional customer service.

Over the last eight decades, we’ve become the injection molding partner of choice for some of the biggest companies in the world. We’re trusted for everything from prototyping and design to tooling creation, secondary services, and supply chain management.

With our experience and quality team, we’re ready to take on even the most challenging projects. Contact us today to learn more about what we can do for you.