Advantages and Applications of Thin Wall Plastic Parts

Conventional wisdom says that thin-wall parts are a more complex and challenging endeavor compared to other subsets of injection molding. That said, the vast array of advantages they offer, from lightweighting to structural benefits, cost savings, cosmetic appeal, and a reduced overall carbon footprint mean that they’re frequently worth the effort – especially in highly demanding electronic and mobility use cases where space is at a premium.

Let’s review some processing methods and material applications currently shaping these markets.

Optimized Part Design and Metal-Insert Molding

Over the last 20 years, the standard for part thickness across electronics and mobility markets has shifted from around 3.5 – 4.0 mm down to 2.5, or even 2.0 mm in some cases. This wall-thickness reduction, driven by factors like lower total vehicle weight targets and sustainability efforts, has been made possible by advances in both resin and software technology.

Using computer aided design (CAD) load-bearing simulations, along with other predictive engineering tools, product designers are capitalizing on the enhanced material properties of modern resins. Thanks to processes like metal insert molding, today’s metal-plastic hybrid parts, for example, perform better while weighing less than the metal components they replace.

What Comparative Tracking Index Measures

Many of the thin-wall-capable resins in our portfolio achieve the Comparative Tracking Index (CTI) performance level of PLC0. Clearing that benchmark is critical for materials used in high-voltage connector designs, since it indicates a minimal breakdown of its insulating properties.

Our supplier partners offer materials that combine CTI PLC0 properties with ultra-thin-wall extrusion and thermoforming capability – while also meeting the UL94 V0 standard at 0.25 mm with non-brominated, non-chlorinated flame retardance.

High Performance Polyamides

Many polyamide and PPO-based materials in our portfolio incorporate non-halogenated flame retardant additives that carry UL, IEC, CCC, CSA approvals.

Thin-wall products made with these materials show a high degree of electrical insulation, in addition to the strength, durability, and chemical resistance that polyamides provide. This makes them excellent for applications like connectors and housings for mobile charging adapters.

Polymer Film Insulation

Poly(p-phenylene oxide)-based (PPO) resins can be used to create a high-performance insulation film used in electric vehicle (EV) battery modules. This type of thin-wall PPO film provides protection against many common risks like:

• Short Circuits
• Fire Propagation
• Chemical Corrosion
• Oil and Grease Stains

A Push for More Sustainable Polymers and Environmental Protection

Markets like mobility are experiencing growing demand and regulatory pressures to invest in more sustainable polymers and reduce the use of PFAS in applications like battery housings, trays, and chargers.

Across materials like polycarbonate, ABS, and polyamide, innovative additives and manufacturing methods are enabling our partners to adapt and achieve more with less material. We’re proud to offer a growing number of products that can declare no intentionally added PFAS.

Ready to Get Started?

Curious about what’s possible with the latest material advances? We’ll work with you to understand your specific needs and develop thin-wall material solutions tailored to your applications.