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IndustrialDesignhaus, LLC

Plastic Part Design

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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.


Plastic Part Design


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.


Plastic Part Design


Modular Power SystemCentral to the Power Receptacle is what

was named the “Wonder Chassis”, because of its many duties in this assembly.


Plastic Part Design


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.


Plastic Part Design


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.


Plastic Part Design


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.


Plastic Part Design


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.


Plastic Part Design


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.


Plastic Part Design


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.


Plastic Part Design


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.

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