	Part Design Checklist

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Plastic Part Design Checklist

Bayer MaterialScience's Application Engineering Group has developed a comprehensive Part Design Checklist for parts produced with injection molded engineering thermoplastics, such as a Makrolon® polycarbonate resin, Apec® high-heat polycarbonate resin, Bayblend® PC/ABS blend resin and Makroblend® PC/PET blend resin. Use the checklist to find technical definitions and illustrations of the key material selection requirements, part design details, assembly considerations and mold concerns you should consider before you finalize your design or build your mold. This is a long page, so you will need to scroll down to access all of the content.

This form is intended to serve as an interactive tool which may be used for obtaining more information on a part design topic before "checking it off." Convenient links are provided for additional information on the Bayer MaterialScience Web Site where applicable. Definitions and illustrations of each topic are presented in a printer-friendly format. As you go along, click the checkboxes for each topic, thereby confirming your consideration of the issues. You can view the entire form by clicking the box at the bottom. This view is printer-friendly, allowing you to print the form for your records.

Use the checklist as an aid to ensure that you consider the important aspects of part design, including material selection, assembly techniques, and mold concerns. The checklist highlights some of the issues that are deemed important, but it is not intended to be a complete list of all the issues concerning part design.

Project:
Other Ref:

Material Selection Requirements
Loads
	Magnitude	Duration	Impact
	Fatigue	Wear
Environment
	Temperature	Chemicals	Assembly
	Outdoor Exposure	Water	Processing
Special
	Transparency	Metallization	Painting/Printing
	Regrind	Cost	Flammability
	Sterilization	Agency Compliance	Shrinkage/Warpage

Part Details Review
Radii
	Sharp Corners	T-Junctions	Lettering
Wall Thickness - Material
	Strength	Other Properties
Wall Thickness - Flow
	Flow Length	Uneven Filling	Flow Direction
	Orientation	Flow Hesitation	Thin-wall Molding
Wall Thickness - Uniformity
	Thick and Thin	Transitions
Ribs
	Base Thickness	Height	Spacing
	Draft & Radius
Bosses
	Wall Thickness	Height	Attachments
Weld Lines
	Strength	Material Difference	Abatement Options
Draft
	Draft Angle	Mold Finish
Tolerances
	Material Shrinkage	Part Geometry	Tool Design
	Geometric Tolerances

Assembly Considerations
Press Fits
	Hoop Stress	Tight Tolerances	Long-term Retention
Snap Fits
	Undercut Design	Assembly Force
Screws
	Thread Cutting vs. Forming	Countersinks
Molded Threads
	Design Nuances	Pipe Threads
Ultrasonics - Welding
	Energy Director	Shear Joint
Ultrasonics - Other
	Staking	Spot Welding	Inserts
Other Welding
	Vibration	Induction	Hot Plate
	Laser	Spin
Adhesive & Solvent Bonding
	Adhesive Families	Adhesive Selection	Joint Design
	Solvent Bonds
General
	Thermal Expansion	Molded-in Inserts	Assembly Tolerances
	Rivets	Component Compatability

Mold Concerns
Warpage
	Cooling (corners)	Ejector Placement
Gates
	Type	Size	Location
	Jetting
Runners
	Size and Shape	Sprue Size	Balanced Flow
	Hang-up Spots	Sharp Corners	Cold-slug Well
General
	Draft	Part Ejection	Long & Thin Cores

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