When selecting materials for designing plastic components in an automotive context, key factors include the mechanical properties such as strength and durability, thermal and chemical resistance to withstand high temperatures and automotive fluids, resistance to water absorption, and UV light exposure before painting. The economic aspects, appearance, and potential hazards are also critical considerations, ensuring that the material meets performance requirements without excessive costs .

The mechanical properties of plastics differ significantly from metals, impacting their application. Plastics are generally more brittle at room temperature as their glass-transition temperature is above ambient. They are more susceptible to variations due to blending and processing compared to metals. While plastics do not corrode like metals and are less dense, their susceptibility to environmental degradation like UV radiation and solvents limits their use in conditions where metals might be preferred. These differences necessitate careful application considerations regarding durability, strength, and environmental exposure .

The use of ribs in the design of plastic parts offers the advantage of increased stiffness without adding significant material mass or cost. Ribs help distribute loads efficiently and can improve the part's overall strength. However, there are disadvantages, including the potential for increased stress concentrations if the ribs are not properly designed with considerations like draft angles, adequate radii, and avoiding excessive rib height relative to thickness. Improper rib designs can lead to production challenges, such as difficulty in mold ejection and potential warping .

Considering the viscoelastic properties of plastics is crucial when designing components expected to experience prolonged stress because this behavior affects how the material deforms over time under constant load. Viscoelasticity leads to creep and stress relaxation, which can compromise the structural integrity and performance of the product over time. Designers need to evaluate the maximum service temperature and time for load application, determine the maximum stress, and use creep modulus to predict deformation accurately, ensuring the durability and reliability of the component .

Plastics can be categorized based on their chemical source into four main types: cellulose plastics, synthetic resin plastics, protein plastics, and natural resins. Cellulose plastics are derived from cotton or wood pulp and include nitrates and acetates. Synthetic resin plastics include phenol formaldehyde, phenolic, urea formaldehyde, vinyl, and styrene. Protein plastics are made from natural sources like milk and soybeans, while natural resins include materials such as shellac, asphalt, and amber .

Processing methods like injection molding and blow molding significantly impact the properties and quality of the final plastic product. Injection molding is optimal for producing complex shapes with high precision and repeatability, offering control over material distribution and minimizing waste. Blow molding is suited for creating hollow parts like bottles, providing uniform wall thickness and smooth surfaces. The choice of method affects the mechanical properties, surface finish, and dimensional accuracy, ultimately influencing the performance and aesthetics of the product .

Ultraviolet (UV) radiation can cause significant degradation in plastic materials, including cracking, fading, or loss of transparency. This degradation affects the material's mechanical and aesthetic properties. Designers can mitigate these effects by selecting UV-resistant materials, incorporating additives or stabilizers that absorb or block UV radiation, and choosing finishes that provide additional protection. Understanding the intended environment and exposure levels is crucial in planning and material selection to ensure long-term durability .

The strain rate affects the mechanical behavior of plastics significantly, with increased rates raising the stress-strain curve, resulting in higher apparent strength but reduced ductility. This behavior must be considered in product design, especially for applications subjected to dynamic loads or impacts, where materials could behave more brittle. Designers must ensure that the plastic can endure the expected strain rates without failure, potentially opting for tougher materials or designing to accommodate changes in stress distribution .

Design choices influence the stiffness of plastic components through the increase of the elastic modulus (E) or the moment of inertia (I). Increasing E can be achieved by adding short glass fibers to materials like nylon. However, increasing I by increasing thickness is less suitable due to higher material costs and cooling issues caused by the low thermal conductivity of polymers. Instead, increasing the number of ribs rather than their height or thickness is preferred to enhance stiffness, helping to maintain structural integrity without incurring significant drawbacks .

Economic considerations significantly impact the material selection process for plastic products. Choosing cost-effective materials that meet design specifications without inflating production costs is crucial. This involves balancing material performance, quality, and price. Designers must consider not only the upfront material costs but also the long-term economic benefits of durability, maintenance, and potential recyclability. This holistic approach ensures that the product remains competitive and sustainable in the market .