MODERN PLASTIC PART DESIGN HANDBOOK: Engineering Injection-Molded Components from Concept to Production Tooling

Design Better Plastic Parts. Understand the Mold. Reduce Costly Manufacturing Problems.** Modern Plastic Part Design Handbook is a practical engineering reference for designing injection-molded plastic components from the earliest concept through production tooling and manufacturing transition. Written for practicing mechanical and manufacturing engineers, this handbook explains why plastic part geometry and injection-mold tooling must be treated as one coupled engineering problem-not as separate design and manufacturing steps. Inside, you will find a quantitative, engineering-focused treatment of: Polymer materials and engineering resin selection Stress, strain, stiffness, fatigue, and structural behaviour Wall thickness, ribs, bosses, and structural features Draft angles, undercuts, and moldability Tolerancing, shrinkage, dimensional stability, and GD&T considerations Snap-fits, living hinges, and assembly features Gates, runners, weld lines, and melt-flow considerations Cooling-system design and cycle-time optimization Warpage, residual stress, and shrinkage Surface finish, cosmetics, and texture Secondary operations and joining methods Prototyping, bridge tooling, production tooling, and DFM review >Rather than presenting isolated rules of thumb, the handbook connects each design decision to the underlying physics and manufacturing consequences. Its chapters build from first principles, include unit-tracked numerical examples, and conclude with worked practice problems. Built for learning-and for reference.** Use it to study injection-molded part design systematically, work through engineering calculations, prepare for design reviews, or return to specific sections when solving real-world design problems. Consistent notation, chapter checklists, worked examples, and quick-reference formula summaries make the handbook useful beyond a first read. The book also demonstrates its methods through capstone cases spanning consumer products, automotive applications, medical devices, startups, high-speed packaging, and sustainability-focused programs. Whether you are learning plastic part design or looking for a deeper engineering reference to support your existing experience, **Modern Plastic Part Design Handbook** provides a structured framework for understanding the decisions that connect plastic geometry, material behaviour, mold design, manufacturing quality, and production economics. From concept to production tooling, learn to design the part and think about the process at the same time.