DESIGN TIP: Cutting Corners on Injection-Molded Parts

Sharp corners definitely have their place in part design, but they often spell trouble when injection molding plastic parts. Accordingly, designers should be aware of the pitfalls associated with “being square” when developing parts. Indeed, part accuracy, strength, and aesthetics suffer without the right amount of corner rounding and filleting.

This month’s design tip explores ways to strengthen injection-molded parts while reducing costs with proper placement of corner radii and fillet. You’ll learn about:

  • Material selection. Some plastics are more forgiving of sharp-cornered parts. Choosing the right one for your application is a necessary step towards accurate, functional parts.
  • Wall thickness. Beefing up adjacent walls may absorb some of the stress associated with sharp internal corners, but can create other design challenges.
  • Part geometry. Some parts are simply more “moldable” than others. Achieving proper form, fit and function depends on sound part design, a large piece of which is appropriate corner radii.

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