π“π¨ππšπ²'𝐬 πŠππŽπ–π‹π„πƒπ†π„ π’π‘πšπ«πž : ππ‹π€π’π“πˆπ‚ πƒπ„π’πˆπ†π ππ€π‘π€πŒπ„π“π„π‘ : ππŽπ’π’ πƒπ„π’πˆπ†π

 π“π¨ππšπ²'𝐬 πŠππŽπ–π‹π„πƒπ†π„ π’π‘πšπ«πž

πŸ”Ή ππ‹π€π’π“πˆπ‚ πƒπ„π’πˆπ†π ππ€π‘π€πŒπ„π“π„π‘ : ππŽπ’π’ πƒπ„π’πˆπ†π

Bosses are used to mount screws, clips, and fasteners in plastic parts.


In automotive plastic design, a boss is not just a hole —

it is a load-bearing feature that must handle:

• Assembly loads

• Clamp

• Vibration

• Repeated service removal


Poor boss design is one of the most common reasons for:

❌ Cracks

❌ Sink marks

❌ Broken mounts


πŸ” Key Boss Design Guidelines (Industry Practice)

• Boss wall thickness should be ≤ 60% of nominal wall thickness

• Boss height should be ≤ 3× boss diameter

• Always core the boss to avoid sink & voids

• Provide fillet at boss base to reduce stress

• Connect bosses to ribs for load transfer


🧠 Industry Insight

Good plastic designers don’t ask:

“Will the screw fit?”

They ask:

“Will the boss survive assembly, vibration, and vehicle life?”


source : iM Technologies

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