Plastic Part & Assembly Design
Plastic components designed for strength, appearance and mouldability.
Good plastic part design is the cheapest quality control you will ever buy. We design plastic parts and assemblies around the realities of injection moulding, with correct wall thickness, ribs, bosses and draft, so parts fill evenly, cool predictably and assemble first time.
From snap fits and living hinges to ultrasonic welding and overmoulding, we combine polymer science with structural analysis to deliver parts that look right, perform reliably and cost less to make.
- Product teams designing new plastic housings, enclosures or mechanisms
- Manufacturers converting metal parts to engineering plastics to cut weight and cost
- Companies with recurring cracking, warpage or assembly failures in existing parts
Plastic part design flow.
Every engagement follows a clear, staged process with defined decision gates, so you always know where your project stands and what happens next.
- 01RequirementsLoads, environment, cosmetics
- 02MaterialPolymer and grade selection
- 03GeometryWalls, ribs, snaps, joints
- 04AnalysisFEA and mould flow
- 05PrototypeTest in production material
- 06◆ GateReleaseDrawings ready for tooling
Plastic Part & Assembly Design services.
Select a service to see what is included, what you receive and the benefits.
Snap Fit & Living Hinge Design
Integrated features that assemble in seconds.
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Metal-to-Plastic Conversion
Lighter, cheaper parts with equal or better performance.
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Plastic Material Selection
The right polymer for performance, process and price.
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Structural FEA for Plastic Parts
Prove strength and stiffness before you build.
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Overmoulding & Insert Moulding Design
Multi-material parts with strong, reliable bonds.
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Plastic Joining & Welding Design
Strong, sealed joints designed for production.
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Parts that mould cleanly
No sink, warp or weak weld lines designed into the part.
Fewer components
Integrated features replace fasteners and secondary operations.
Proven performance
Load cases checked by analysis before the first tool is built.
Plastic Part & Assembly Design: common questions.
Can you convert a metal part to plastic?
Yes. We select a suitable engineering polymer, redesign the geometry for moulding and validate strength with FEA, often consolidating several metal parts into one moulding.
Which plastics do you work with?
Commodity and engineering grades including PP, ABS, PC, PC/ABS, nylon (PA6, PA66), POM, PBT, TPE and glass- or mineral-filled variants.
Single-part design reviews in 1–2 weeks; full assembly design programs over 4–12 weeks.
Every engagement starts with a free consultation and a fixed-scope proposal with clear deliverables, timing and success measures.
Articles on Plastic Part Design.
Designing in alternate resins to reduce supply risk
Products designed around a single resin grade are exposed to price spikes, shortages and discontinuation. How to design and qualify alternate materials in advance, so you can switch quickly when supply is disrupted.
Designing plastic parts for recyclability
Recyclability is decided at the design stage: material choices, joining methods, labelling and colour all determine whether a part can be recovered. Practical design rules for plastic parts that can be recycled at end of life.
Case studyCase study: designing an electronics enclosure for recyclability
A European customer required a consumer electronics brand to show how its products could be recycled. Cutting material types from seven to three, replacing screws with snap fits and moulding in labels raised recyclable mass from 61% to 94% and cut disassembly time from 140 to 55 seconds.
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Whether it’s a bold new product, a strategy that needs sharpening or an operation that should be doing more, a conversation with a senior consultant is the fastest way to find out what’s possible.
- Free initial consultation with a senior engineer
- Response within one business day
- Confidentiality and NDA available on request
Prefer to give us the full picture? Use the detailed project enquiry form