INJECTION

MOLDING
DESIGN GUIDE
The Injection Molding
Process
Injection molding is a fast and efficient way to produce
plastic parts. The tool that it uses, an injection mold, has
two main parts: the core and the cavity. These two halves
of the mold come together, and molten plastic is injected
into the tool.
Once the molten plastic cools, the two halves of the
mold separate and the part is ejected. Depending on the
construction of the mold and the part quantities that you
need, this process can be repeated tens, hundreds, or many
thousands of times.
That’s just a high-level overview, of course, but it lays the
groundwork for the details you’ll find in this design guide.
As you keep reading, remember that injection molding
design is a three-part process.

1 Start your design

2 Upload your design and get design for manufacturing

(DFM) feedback

3 Review part samples

This guide covers it all. Let’s get started.

Injection Molding Design Guide | 2

 Step 1: Start Your Design
Starting your part design comes with ten
major considerations.

Step 1: A Material Selection

Start Your B Wall Thickness

Design C Transitions

D Corners

E Draft

F Ribs and Bosses

G Tolerances

H Parting Lines

I Gates

J Ejector Pins

Injection Molding Design Guide | 3

 Material
Selection

STEP 1: Start Your Design

 A Material Selection INJECTION MOLDED PLASTICS

Injection molding materials range from commonly used

Resin Characteristics
polymers to specialty plastics and polymer blends. There
are literally hundreds of different plastic resins available, and Polyether Ether Excellent mechanical properties and resistance to
they each have different end-use properties and processing Ketone (PEEK) chemicals and thermal degradation
requirements. Plus, there can be different grades of the same
Polyetherim- Combines stiffness and stability with low flammability
plastic material, including resin types with glass fibers or ide (PEI) and low smoke production
carbon fibers.
Polyethylene Generally used for indoor applications. Chemically
(PE) resistant. Includes high and low-density materials.

INJECTION MOLDED PLASTICS Polyphenyl- High toughness, high flexural and tensile strength,
sulfone (PPSU and good resistance to chemicals and heat
Resin Characteristics
Polypropylene Good chemical resistance and won’t degrade when
Excellent rigidity and thermal stability with low water (PP) exposed to moisture or water
Acetal (POM)
absorption and good chemical resistance
Lightweight, relatively inexpensive, and resistant to
Polystyrene
Acrylic Strong, lightweight, shatter-resistant, optically clear, moisture and
(PS)
(PMMA) and UV and weather-resistant bacterial growth

Acrylonitrile Thermoplas-
Strong and impact-resistant, even at low tempera- Processed like plastic but has the properties and per-
Butadiene tic Elastomer
tures formance of rubber
Styrene (ABS) (TPE)

Tough with high heat resistance, high abrasion resis- Thermoplastic

Nylon (PA) Rubber-like elasticity with good load-bearing capa-
tance, and good fatigue resistance Polyurethane
bilities
(TPU)
Polybutylene
Resistant to creep and used in parts with thin
Terephthalate
cross-sections
(PBT)

Polycarbonate Strong, lightweight, and naturally transparent, with

(PC) stable properties over a wide temperature range

STEP 1: Start Your Design Injection Molding Design Guide | 5

 Wall
Thickness

STEP 1: Start Your Design

 B Wall Thickness B Wall Thickness
Wall thickness affects the strength, cost, and appearance of Wall thickness affects the strength, cost, and appearance
your injected molded part. Simply put, it’s one of the most NON-UNIFORM
of your injected molded [Link] THICKNESS
Simply put, it’s one of the
important design considerations. most important design [Link]
Can cause distortion when

There are three wall thickness terms that designers need to There are three wall thickness terms that designers need to
understand: understand:
• Uniform wall thickness • Uniform wall thickness
• Nominal wall thickness • Nominal wall thickness
• Recommended wall thicknesses • Recommended wall thicknesses SINK

UNIFORM WALL THICKNESS UNIFORM WALL THICKNESS

Whenever possible, apply a uniform wall thickness to your Whenever possible, apply a uniform wall thickness to your
AS MOLDED
part. This best practice promotes more consistent cooling and, part. This best practice promotes more consistent cooling
consequently, more consistent shrinking. and, consequently, more consistent shrinking.
You can use walls with different thicknesses, You can use walls with different thicknesses,
but they’ll cool and shrink at different rates. but they’ll cool and shrink at different rates.
This may cause sink, warp, and other injection molding This may cause sink, warp, and other injection molding
defects. defects.

WA RP

AS MOLDED

STEP 1: Start Your Design Injection Molding Design Guide | 7

NOMINAL WALL THICKNESS
RECOMMENDED WALL THICKNESS
Nominal wall thickness is the thickness throughout your part. A
uniform wall thickness is recommended, but it’s also important Resin in mm
to avoid walls that are too thick or too thin.
Polycarbonate
• Walls that are too thick require more plastic material and 0.040–0.150 1.02–3.81
(PC)
longer machine cycle times, both of which add costs to
your project. Polyether Ether
0.020-0.200 0.508-5.080
Ketone (PEEK)
• Walls that are too thin may trap air where the plastic
doesn’t fill the mold completely. These “short shots” result Polyetherimide
0.080-0.120 2.032-3.048
(PEI)
in incomplete parts.
In addition, keep wall thickness (or thicknesses) within range Polyethylene
0.030–0.200 0.76–5.08
(PE)
for the plastic material you’ve selected. The next section lists
the recommended wall thicknesses for common plastic resins.
Polyphenylsul-
0.030-0.250 0.762-6.350
phone (PPSU)

Polypropylene
RECOMMENDED WALL THICKNESS 0.040–0.150 1.02–3.81
(PP)

Resin in mm Polystyrene
0.025–0.125 0.64–3.18
(PS)
Acetal (POM) 0.030–0.120 0.76–3.05
Thermoplas-
Acrylic (PMMA) 0.025–0.150 0.025–0.150 tic Elastomer 0.025–0.125 0.64–3.18
(TPE)

Acrylonitrile
butadiene 0.045–0.140 1.14–3.56 Thermoplastic
styrene (ABS) Polyurethane 0.025–0.125 0.64–3.18
(TPU)

Nylon (PA) 0.030–0.115 0.76–2.92

Polybutylene If you can’t maintain a uniform wall thickness throughout your

Terephthalate 0.080-0.250 2.032-6.350 design, use smooth transitions between sections with different
(PBT)
thicknesses.

STEP 1: Start Your Design Injection Molding Design Guide | 8

 Transitions

STEP 1: Start Your Design

 C Transitions There are two main ways to achieve these transitions:
chamfers and fillets.
Best practice is to smooth, or blend, transitions between
areas with different wall thicknesses to minimize stress • Chamfers are angled edges where two surfaces meet.
concentrations that can result in part failure. • Fillets are rounded corners or edges.

THICKNESS TRANSITIONS
Blend transitions to
minimize read-through

Smooth transitions aren’t the only way to avoid stress

concentrations, however. Using rounded corners instead of
sharp ones can help.

STEP 1: Start Your Design Injection Molding Design Guide | 10

 Corners

STEP 1: Start Your Design

 D Corners
Sharp edges don’t just concentrate stresses. They also increase
CORNER DESIGN
part costs because they require molds that are made with
Internal and external corner radii should
electrical discharge machining (EDM).
originate from the same point

Sharp corners are a good place for parting lines, as we’ll see
later in this guide, but it’s best to use them wisely and, where
possible, use rounded corners instead.

Rounded corners limit stress concentrations and minimize

differences in shrinkage as the plastic material cools. They also
help to control tooling costs and enable the molten plastic to
flow more readily throughout the mold.

When you apply rounded corners to your part design, follow

these guidelines:
• Make the internal radius at least 50% of the wall thickness
• Make the external radius the sum of the inside radius and
the wall thickness
• Start the internal and external corner radii from the same
point

STEP 1: Start Your Design Injection Molding Design Guide | 12

 Draft

STEP 1: Start Your Design

 When specifying the amount of draft to apply, consider the
E Draft
following.
Draft is an angle you apply to vertical walls so that parts will
• The resin you’re using
eject cleanly from the mold. This taper can also decrease tool
wear and reduce cooling times, both of which help to control • The standards you’re following
costs. • The part’s finish
• The mold’s construction

RESINS
Draft angles vary by the type of resin, or injection molding
material. There are also different systems, or standards, that
define the amount of draft to apply.

STANDARDS
Trade associations and companies define standards and
designations for injection molding finishes, which include
textures and polishes.
• The Society of the Plastics Industry (SPI) and the Society of
German Engineers / Verein Deutscher Ingenieure (VDI) are
two of these trade associations.
• Mold-Tech (MT) and Yick Sang (YS) are companies that have
developed their own standards.

COMMON DRAFT GUIDELINES

STEP 1: Start Your Design Injection Molding Design Guide | 14

This is why you’ll hear terms like “SPI finishes” and “Mold Tech In general, it’s best to add 1.5° of draft per 0.001” or 0.025 mm
textures” during DFM discussions. of textured depth. SPI, VDI, MT, and YS publish tables with
recommended draft angles.

Polish isn’t a function of draft, but it’s worth mentioning here

because — as with texture — the finish for your part is imparted
by the finish of your mold.

MOLD CONSTRUCTION
Finally, remember to set the draft angle based on the mold’s
draw, or how it separates. Otherwise, the part may not stay
in, or stick to, the half of the mold that contains the ejector
system. Consider both the draft on the part’s vertical walls and
on part features.

FINISH
Draft is related to the texture of your injection molded For example, in the case of a rectangular part with four
parts. During injection molding, the texture that you want is through-holes, drafting the holes toward the cavity could
transferred from the mold to part surfaces. cause parts to stick there instead of to the core. A better
approach would be to draft the holes toward the core where
the ejector system is located.
Smoother finishes require less draft and finishes with heavier
textures require more draft.

• Smooth Finish: 1 to 2 degrees (typical)

• Light Texture: 3 degrees
• Heavy Texture: 5 degrees or more

STEP 1: Start Your Design Injection Molding Design Guide | 15

 Ribs and
Bosses

STEP 1: Start Your Design

 RIBS
F Ribs and Bosses
Ribs are vertical features that add structural integrity and
Injection molded parts have thin walls to support faster
increase load-bearing capacity.
production speeds and longer mold life. Yet thin-walled parts
Thick ribs are prone to shrinkage, however, as this chart
may lack sufficient strength. Ribs and bosses increase part
shows.
strength, but there are some key rules to follow when adding
them to your design.

RIB THICKNESS VS SHRINKAGE

GOOD DESIGN OF RIBS & BOSSES

RIB THICKNESS RATIO (TH/W)

POLYMER SHRINKAGE (IN/IN)

STEP 1: Start Your Design Injection Molding Design Guide | 17

If a rib is too thick, sink marks may appear on its opposite side
RIB DESIGN G UIDELINES
and mar the part’s finish.
*Minimum 0.5° per side

SINK
OPPOSITE
THICK RIB

To avoid these problems, follow these best practices: MULTIPLE RIBS

Replace large problematic ribs with
• Wall Thickness: Make the rib’s wall thickness 50% to 60% (0.5
multiple shorter ribs
to 0.6 T) as thick as the nominal wall.
• Fillets: Add a fillet to the bottom of the rib. Keep the radius
of this fillet near 0.25T-0.5T, where T is the nominal wall
thickness. Don’t exceed 0.010 inches for the radius.
• Height: Keep ribs as short as possible and do not exceed 2.5T.
If the height of a rib is a problem, use multiple shorter ribs.
• Draft: Apply draft to ribs and use at least 0.5 degrees per side.

STEP 1: Start Your Design Injection Molding Design Guide | 18

BOSSES
CONNECTING BOSSES TO WALL
Bosses are vertical features that support assembly and increase
a part’s structural integrity. They can accommodate fasteners
such as screws and, as with dowel pins, smaller bosses can be
inserted into larger bosses within walls.
When designing bosses, remember the following:
• Location: Place bosses where more structural integrity is
needed, such as at screw slots.
• Diameter: Don’t make the holes too small — they will
shrink as they cool.
• Thickness: Avoid sink marks by making the boss thickness
no more than 60% of the overall wall thickness.
• Walls: Consider how bosses will attach to walls — they
need to align properly.
BOSS IN ATTACHMENT WALL
Open bosses maintain uniform 
thickness in the attachment wall

TYPICAL BOSS
DESIGN

STEP 1: Start Your Design Injection Molding Design Guide | 19

 Tolerances

STEP 1: Start Your Design

G Tolerances
Injection-molded parts that are used in larger assemblies need to have correct and consistent dimensions. Because some degree of
dimensional deviation is expected in any process, designers need to define a part’s acceptable dimensional variations or tolerances.

There are two main types of injection molding tolerances.

• Commercial tolerances are less precise, require lower-cost molds, and produce lower-cost parts.
• Fine tolerances are more precise, require higher-cost molds, and produce higher-cost parts.

Like wall thickness and draft, dimensional tolerances vary by resin. There are also different tolerances for overall sizing and for
specific part features.

• Dimensional: Overall sizing of the part

• Straightness or Flatness: Covers the general warping of large, flat areas
• Hole Diameter: Larger holes need larger tolerances because of increased shrinking
• Concentricity/Ovality: A large cylindrical part with a thin wall can shrink unevenly

For mating parts, consider the tolerance stack-up as well. This refers to how all of the components in an assembly, and their
individual tolerances, must fit together.
For example, an assembly has three parts, each with a screw hole. The hole in each part is within tolerance, but the holes must align
so the screw can pass through all of them.

STEP 1: Start Your Design Injection Molding Design Guide | 21

 Parting Lines

STEP 1: Start Your Design

H Parting Lines
Injection molds have a parting line where the tool opens and
closes. Sometimes, the parting line is right down the middle of
the injected molded part. That’s usually what designers think
of when they envision a parting line, but that’s not always the
case – or even a best practice.

Take, for example, a LEGO® brick. The parting line is not down
the top-middle of the brick, where it would be very noticeable.
Rather, the parting line is along the brick’s bottom edges so
that you have to turn over the brick to see it.

Sharp edges concentrate stresses but they’re a good place for

parting lines because they simplify mold construction, which
helps to reduce project costs. Avoid filleted surfaces, however,
because they don’t work well with parting lines:

• Filleted surfaces require a tight tolerance mold, which

increases costs.
• They increase the risk of flash, an injection molding defect
that can occur when the two halves of the mold don’t
come together cleanly.

STEP 1: Start Your Design Injection Molding Design Guide | 23

 Gates

STEP 3: Review Part Samples

 I Gates
Gates are openings in an injection mold that allow molten
plastic to enter the cavity.

• Gate size is important because larger parts need larger

gates to support higher-volume flow.
• Gate location matters because gates can determine where
warping occurs, or where there are weld lines, sink marks,
voids, or other injection molding defects.

Designers also need to consider gate location because gates

leave plastic protruding from the part’s surface. This extra
plastic gets trimmed, but it’s best to put gates where any small
marks that are left behind are least noticeable. Often, gates are
placed along the mold’s parting line.

Trimming provides a way to categorize gates, but specific

types of gates are recommended for parts with specific part
features. Some gates require manual trimming. Others support
automatic trimming where excess material is sheared during
part ejection.

STEP 1: Start Your Design Injection Molding Design Guide | 25

MANUALLY TRIMMED GATES
• Edge or standard gates are recommended for flat parts. The gate’s cross-section is rectangular and can be tapered.
• Fan gates have a large opening with a variable thickness. They permit the rapid filling of large parts and fragile mold sections.
• Tab gates are used with thin, flat parts that require low shear stresses. A tab-like feature confines these stresses to the gate area.
• Direct or sprue gates are used with large, cylindrical parts. A sprue feeds material directly and rapidly into the cavity.
• Disc or diaphragm gates are used with round or cylindrical parts that require concentricity. Typically, these injection molding
gates are difficult to remove and expensive to trim.
• Ring gates allow material to flow freely before moving into a uniform, tube-like extension for mold filling.
• Spoke gates are round gates that have a cross in the middle. They’re used to produce tube-shaped parts, but perfect
concentricity is difficult to achieve.

AUTOMATICALLY TRIMMED GATES

• Hot tip gates support conical or round shapes that require uniform flow into the mold cavity. They are used in hot runner
systems that keep the plastic in a molten state until it enters the cavity.
• Submarine or sub gates have a tapered channel and can help hide gate blemishes. These openings are sometimes called tunnel
gates.

• Pin gates are used with fast-flowing resins and when a part’s cosmetic appearance is important. Pin gates are used typically with
parts that cannot have vestiges on either side of the parting line.

STEP 3: Review Part Samples Injection Molding Design Guide | 26

 Ejector Pins

STEP 1: Start Your Design

 J Ejector Pins For best results, locate ejector pins on part surfaces that are
not visible. There are other guidelines to consider as well —
Ejector pins are used to eject a part from a mold after cooling
some are a function of the mold-making process, but part
is complete. Sometimes, however, the mold sticks, which
designers need to understand them in order to evaluate
causes marks from the ejector pins to appear on the finished
tooling.
part.

• Distribute the ejection force as evenly as possible to

prevent part deformation.
• Apply the ejection force to the area of the part with the
greatest strength and rigidity.
• Avoid placing ejector pins on thin areas or sloped surfaces.
• Locate ejector pins away from the sliding track that the
mold uses.
• Use an ejector mechanism with sufficient strength and
wear resistance.

Now that you’ve started your part design and defined some
key characteristics, it’s time to upload your design and get
expert DFM feedback from Fictiv.

STEP 3: Review Part Samples Injection Molding Design Guide | 28

 Step 2: Upload Your Design and Get
Expert DFM Feedback
Fictiv provides DFM feedback along with your request for a
quote. Just create a free Fictiv account, upload your CAD file,
and then review and incorporate the feedback using the 3D

Step 2:
visualization tool built-in to the Fictiv platform.

Upload
Your
Design and
Get Expert
DFM
Feedback
[Link]/login

Injection Molding Design Guide | 29

Most manufacturers won’t provide DFM feedback until you place an order, but Fictiv provides a full DFM analysis for free along with
your quote. At this stage, the aim is to discover all of the potential issues or risks for mold making and injection molding.

Here are a few common DFM questions that Fictiv’s engineers will answer when you work with us:

• Will the location of the gate cause cosmetic defects?

• Will the parting line leave a noticeable mark?
• Will ejector pins noticeably mar the part or risk damage?
• How will plastic flow into the mold and form what’s known as a knit line (weld line), where two flow fronts meet?
• Are there additional risks, such as hard-to-achieve tolerances?

The DFM stage is critical because when your part is still being designed, small modifications typically take just a few minutes or
hours to complete. After your tooling is cut, however, it can take at least a few days and hundreds of dollars just to make a small
tooling change.

By working with Fictiv and incorporating the expert DFM feedback that you receive from us, you’ll be ready for mold-making and
part sampling. You’ll also get access to a highly-vetted network of local and overseas injection molders, as well as a dedicated U.S.
service team.

STEP 2: Upload your Design and Get Expert DFM Feedback Injection Molding Design Guide | 30
 Step 3: Review Part Samples
During Step 1 of the injection molding design process, you’ll
consider how the injection mold that will be used to produce
your parts can affect part costs and quality. During Step 2,
Fictiv reviews your design for manufacturability.

Step 3: In the final step of the injection molding design process, a tool
maker will create your mold and an injection molder will send

Review you part samples. Because your part design may change based
on the trial samples that you receive, there are a few more
steps to consider.
Part
Samples A Mold Making

B Sample Parts

C Begin Production

Injection Molding Design Guide | 31

 Mold Making

STEP 3: Review Part Samples Injection Molding Design Guide | 32

 A Mold Making
After you submit your part design for tooling, a mold maker
will cut the steel or aluminum that’s used for the core and
cavity. Bench workers will then assemble the mold, incorporate
off-the-shelf parts such as ejector pins, and test the mold for
leaks.

For new product introduction (NPI), Fictiv recommends

starting with a single-cavity tool because these molds are
less expensive to make and take less time to produce. That’s
important since your design may change and require new
tooling.

When your design is truly final, you can ramp up production

by ordering multi-cavity molds or family molds that combine
different part numbers into the same mold base.

STEP 3: Review Part Samples Injection Molding Design Guide | 33

 Sample Parts

STEP 3: Review Part Samples Injection Molding Design Guide | 34

 B Sample Parts
Use the sample parts that you receive to perform functional testing and dimensional measurements. Expect your samples to be
within the tolerances you’ve specified and very close to meeting all of your requirements.

If your part design included a textured finish, your sample parts will include this as well. There are hundreds of texture options, so
make sure the light, medium, or heavy texture you’ve received is satisfactory.

If your sample parts require adjustments, submit an engineering change order. For example, you might need to tighten up some
tolerances. Then, when you’re satisfied with your samples, it’s time for production.

The information in this chart is provided in good faith, based on Fictiv employee experience with traditional manufacturers, and is provided “As Is” without warranty of any kind (express or implied).

STEP 3: Review Part Samples Injection Molding Design Guide | 35

 Begin
Production

STEP 3: Review Part Samples Injection Molding Design Guide | 36

C Begin Production
After you’ve approved your part samples, injection
molding production can begin. Depending on the tool’s
construction, you can get tens, hundreds, or many
thousands of parts.

Because Fictiv doesn’t have minimum order quantities

Minimizing Risk During
(MOQs), remember that you can ramp up production Product Launch
gradually to match customer demand.
As you’ve learned from this guide, there’s
much to consider when designing injection
molded parts. But don’t worry! Partnering
with Fictiv means that we’ll shoulder the
heaviest parts of the burden. Count on our
guided expertise to improve your design and
ensure a successful product launch.

Create your free Fictiv account

and upload your part drawing at
[Link]/signup

STEP 3: Review Part Samples Injection Molding Design Guide | 37

 LEAD TIME | T1 samples as fast as 10 days
Injection
QUALITY ASSURANCE
Molding • Standard: SPI Commercial Tolerances & Inspection Reports
High quality tooling, • Available: SPI “Fine” Tolerances, Material Certifications,
done your way. CoCs

Online quotes in 24 hours with free DFM

TOOLING TYPES & FINISHES | Types: Single Cavity, Multi-
Complex geometries accepted
Cavity, Family Tooling. Finishes: Glossy, Semi-Glossy, Matte,
Support from a U.S.-based team Textured
of tooling experts

TOOLING MATERIALS | P20 Steel, NAK80 Steel, H13 Steel,

Stainless Steel, Aluminum

SECONDARY OPERATIONS | Pad Printing, Silkscreen Printing,

Painting, Laser Etching, Ultrasonic Welding, Insert Heat
Staking, Insert Molding

GEOGRAPHIES | U.S. & overseas options available

INJECTION MOLDING MATERIALS | All commercially

available materials + custom materials

PRESS SIZES | 50-3,300 ton machine presses

[Link]