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IndustrialDesignhaus, LLC
Plastic Part DesignPage 1
© 2011 Industrial Designhaus, LLC. All rights reserved.
Plastic Part DesignPlastic part design is something we do on an every-day basis. The following pages feature some past projects and highlight areas of our design where clever solutions saved the client money in tooling, part costs, or both.
IndustrialDesignhaus, LLC
Plastic Part DesignPage 2
© 2011 Industrial Designhaus, LLC. All rights reserved.
Modular Power SystemThis Modular Power Receptacle is part of a
modular power system for office spaces, and employs a wide variety of plastic and sheet metal materials, including PC/ABS
and Nylon. One of the project challenges was meeting various electrical standards while keeping part and tooling costs low.
IndustrialDesignhaus, LLC
Plastic Part DesignPage 3
© 2011 Industrial Designhaus, LLC. All rights reserved.
Modular Power SystemCentral to the Power Receptacle is what
was named the “Wonder Chassis”, because of its many duties in this assembly.
IndustrialDesignhaus, LLC
Plastic Part DesignPage 4
© 2011 Industrial Designhaus, LLC. All rights reserved.
Critical PartThe Wonder Chassis secures all Bus Bars and Simplex
parts, as well provides means for the assembly to snap into place with other power modules, all with no need of
side actions within the tooling.
Creative MoldingRetaining prongs secure
brass parts in place and are created with shut-off features in the mold.
IndustrialDesignhaus, LLC
Plastic Part DesignPage 5
© 2011 Industrial Designhaus, LLC. All rights reserved.
Mesh Tape ApplicatorThis hand tool for the drywall field contains
multiple injection-molded plastic parts as well as sheet metal parts.
Several creative solutions permitted inexpensive
tooling for the plastic parts.
IndustrialDesignhaus, LLC
Plastic Part DesignPage 6
© 2011 Industrial Designhaus, LLC. All rights reserved.
Creative MoldingApparent undercut snaps in flexible PP Reel parts are molded as shut-offs to
avoid costly side-actions in tooling. This results in low-cost Reels to fit both
2” and 3” diameter tape cores.
IndustrialDesignhaus, LLC
Plastic Part DesignPage 7
© 2011 Industrial Designhaus, LLC. All rights reserved.
Creative Part DesignMirror-image Nylon 6 Arms require only a single cavity mold and lock to one another in assembly, capturing sheet metal spring and release buttons.
IndustrialDesignhaus, LLC
Plastic Part DesignPage 8
© 2011 Industrial Designhaus, LLC. All rights reserved.
Simplified AssemblySingle screw attaches Handle firmly to sheet metal Chassis for quick, strong, inexpensive assembly.
Section ViewPP Handle, four-piece mold.
Strong and EffectiveBoss accepts screw, pips fit into holes in sheet metal Chassis to keep handle from twisting under load.
IndustrialDesignhaus, LLC
Plastic Part DesignPage 9
© 2011 Industrial Designhaus, LLC. All rights reserved.
Details with EDMFine details were carefully added to the tooling using
EDM electrodes, resulting in an excellent part quality.
Electronics EnclosureThese enclosure parts were required to meet stringent UL testing standards while maintaining a pleasing aesthetic for household use. Two pieces capture all the parts in the assembly.
IndustrialDesignhaus, LLC
Plastic Part DesignPage 10
© 2011 Industrial Designhaus, LLC. All rights reserved.
Smart ContainerThe Smart Container features few
corners and the ability to stack.
Challenges included a friction fit to hold the Knife in the Lid and getting a reliable
seal between Lid and Tub, particularly along the straight edges.