CA LC U L AT I O N S D ES I G N A PPL I CAT I O N S B . 3 .

1
snap fit joints in plastic parts
Design calculations for
Contents

1. Introduction 3

2. Requirements for snap-fit joints 3

3. Basic typesof snap-fit joint 4

3.1 Barbed leg snap-fit 4

3.2 Barbed leg snap-fit supported

on both sides 4
3.3 Cylindrical snap-fit 4
3.4 Ball and socket snap-fit 5

4. Critical dimensions for snap-fit joint

a 6
4.1 Maximum permissible undercut depth Hmax.
and maximum permissible
elongation s,^ 6
4.2 Elastic modulus E 10
4.3 Coefficient of friction M 10
4.4 Assembly angle a\ and retaining angle 2 11

5. Design calculations for snap-fit joints 12

5.1 Barbed leg snap-fit 12

5.2 Cylindrical snap-fit 13
5.3 Ball and socket snap-fit 14

6. Calculation examples 16
6.1 Barbed leg snap-fit 16
6.2 Cylindrical snap-fit 16

6.3 Ball and socket snap-fit 18

6.4 Barbed leg snap-fit supported
on both sides 18

7. Demoulding ofsnap-fit joints 20

8. Applications 21
8.1 Barbed leg snap-fit 21
8.2 Cylindrical snap-fit 23
8.3 Ball and socket snap-fit 24

9. Explanation of symbols 24

10. Literature 25
1. Introduction 2. Requirements
for snap-fit joints
Snap-fits are formfitting joints which permit great design Snap-fits are used to fix
parts together in a certain
two

flexibility. All these joints basically involve a projecting position. In some cases,important to exclude play
it is
lip, thicker section, lugs or barbed legs moulded on one between the assembled parts (e. g. rattle-free joints
part which engage in a corresponding hole, recess or for automotive applications). The axial forces to be
undercut in the other. During assembly, the parts are transmitted are relatively small. In the majority of appli
elastically deformed. Joints may be non-detachable or cations, the joints are not subject to permanent loads
detachable, depending on design (figs. 4 and 5). Non- (e. g. from internal pressure).
detachable joints can withstand permanent loading even
at high temperatures. With detachable joints, it is neces Special fasteners such as rivets and clips also work on the
sary to test in each individual case the permanent load snap-fit principle. They should be easy to insert, suitable
deformation which can be permitted in the joint. In the for blind fastening, require low assembly force and be
unloaded state, snap-fit joints are under little or no stress able to bridge the tolerances of the mounting hole.
and are therefore not usually leaktight. By incorporating
sealing elements, e.g. O-rings, or by using an adhesive,
leaktight joints can also be obtained.

Snap-fits are one of the cheapest methods of joining

plastic parts because they are easy to assemble and no
additional fastening elements are required.

Hostaform
Acetal copolymer (POM)

Hostacom
Reinforced polypropylene (PP)

Celanex
Polybutylene terephthalate (PBT)

@Vandar
Impact-modified
polybutylene terephthalate (PBT-HI)

lmpet
Polyethylene terephthalate (PET)

=
registered trademark
 The undercut depth H is the difference between the
3. Basic types of snap-fit joint outside edge of the barb and the inside edge of the hole
(% 1):
The parts with an undercut can be cylindrical, spherical
or barbed. There are three corresponding types of snap- undercut depth H =
LI L2 (1)
fit joint:
The leg is deflected by this amount during assembly.
1 .
Barbed leg snap-fit
2. Cylindrical snap-fit In designing a barbed leg, care should be taken to pre
3. Ball and socket snap-fit vent overstressing at the vulnerable point of support
because of the notch effect. The radius r (fig. 1) should
therefore be as large as possible.
3.1 Barbed leg snap-fit

Hg.l 3.2 Barbed leg snap-fit supported on both sides

Fig. 3

1, Pj
i
-\ T S (/}

_vu HJ1 t
T t
-1 >~
1
/R

Barbed spring elements supported on one or

legs are This joint employs a barbed spring element supported
both sides and usually pressed through holes in the on both sides. The undercut depth H is the difference
mating part (fig. 1). The hole can be rectangular, circular between the outside edge of the barb and the width of
or a slot. The cross-section of the barbed leg is usually the receiving hole (fig. 3). Hence as in formula (1) we
rectangular, but shapes based on round cross-sections are obtain:
also used. Here, the originally cylindrical snap-fit is
divided by one or several slots to reduce dimensional undercut depth H Lt L2 (la)
rigidity and hence assembly force (fig. 2).
Thissnap-joint may be detachable or non-detachable
Fig.2 depending on the design of the retaining angle.

3.3 Cylindrical snap-fit

Cylindrical snap-fits consist of cylindrical parts with a

moulded lip or thick section which engage in a corre
sponding groove, or sometimes just a simple hole in the
mating part.
 Fig. 4: Non-detachable joint compression ( ) of the shaft
^1DG
^ _==*. 100% (4)
UG

elongation (+) of the hub

AV*
e2 = + ~^-WO%
,

(5)
i-TC

As it is not known how the undercut

depth H is appor
tioned between the mating parts, it is assumed for sim
plicity that only one part undergoes a deformation e
corresponding to the whole undercut depth H.

H
s
Dr,
-100% or e=^^-100%
DK

3.4 Ball and socket snap-fit

Fig. 5: Detachable joint
Fig. 6

The difference between the largest diameter of the

shaft DG and the smallest diameter of the hub DK is the
undercut depth H. Ball and socket snap-fits (fig. 6) are mainly used as motion
transmitting joints. A ball or ball section engages in a

undercut depth H =
DG DK (2) corresponding socket; the undercut depth H is the differ
ence between the ball diameter DG and the socket open
DG largest diameter of the shaft [mm] ing diameter DK.
DK smallest diameter of the hub [mm]
undercut depth H =
DG DK (7)
The parts are deformed by the amount of this undercut
DG ball diameter [mm]
depth during assembly. The diameter of the shaft is
DK socket opening diameter [mm]
reduced by ADC, and the diameter of the hub increased
by +ZlDK.
Because the shaft is solid and therefore very rigid, the
hole undercut depth H must be overcome by expanding
So the undercut depth can also be described as
the hub. As a result of this diameter change, the hub is
deformed as follows:
H =
ADC + JDK (3)

As result of these diameter the shaft and hub , - DG-DK H

a changes, elongation e =
^ 100% = 100% (8)
deformed
jL>K DK
are as follows:
 the deformation is lower. So barbed
4. Critical dimensions legs are stressed
much less than cylindrical snap-fits. As a result of this,
for a snap-fit joint higher elongation is permissible and in many cases is
necessary for design reasons.

Irrespective of the type of

snap-fit there is a linear relation For non-rectangular barbed leg cross-sections, the follow
between the undercut depth H and elongation e. The ing relationships apply between undercut depth H and
maximum permissible undercut depth Hmax. is limited by deformation e in the outer fibre region (outer fibre elon
the specified maximum permissible elongation e^^ .
gation):

The load-carrying capacity of snap-fits depends on the

elastic modulus E and coefficient of friction //. It can be semicircular I2 en
matched to the requirements of the joint by adjusting Hmax.= 0.578 (10)
cross-section r 100
undercut depth H and assembly angle i or retaining
angle K2 (see section 4.4).
third of a circle I2 en
Hmax. = 0.580 (H)
cross-section r 100

4.1 Maximum permissible undercut depth Hm and

maximum permissible elongation &max. quarter of a circle
cross-section
Hmax.= 0.555-^-^- (12)
In barbed legs (fig. 7), the following relation applies
between undercut depth H (= deflection) as a result of
deflection force FB and elongation or compression in the These relationships also apply approximately to leg
outer fibre region of the barbed leg cross-section cross-sections in the form of sectors of an annulus.
(rectangular section):
A comparison between formula 9 and formulae 10 to

12 shows that the maximum permissible undercut

undercut depth Hmax. =
-|- - ^
-

(9)
depth Hmax. for barbed legs with cross-sections in the
form of segments of a circle is 15% lower than that of
barbed leg length [mm] a rectangular barbed leg cross-section (assumption:

barbed leg height [mm] h -I).

x. permissible elongation [/o]
The maximum permissible undercut depth Hmax. for
barbed legs of different length and height with a
Fig. 7
rectangular cross-section can be read off figs. 10 to 13.

Kg- 9

\ a
'fi
s \

in cross-section A- A
'T n t
Fig. 8: Elongation (fig. 7)

1
The maximum permissible undercut depth Hmax. for
barbed leg snap-fits supported on both sides can be
calculated with the aid of fig. 14, irrespective of the
The maximum deformation (fig. 8) only applies in the material. Fig. 14 applies for emax 6% (see calculation
=

critical region A -

A, fig. 7, while in other cross-sections example 6.4).

Fig. 10: Maximum permissible undercut depth Hn Fig. 12: Maximum permissible undercut de
for Hostaform and Hostalen PP for Hostacom M 4 N01 and G 3 N01

a
2% s 1=50 mm
3

o^ ~13^ max. =

s_
H
i

<^i ~
LU u=L ^|
4^
1 E
X i"
f \ |5
mm
n *iln*L max. = 8%
: \ Vl = 30 mrr [
30
y&^ N Hmax. oj s,
V >
s
X
^
M

20
\
depth x= 20 mn

S Is
KJ ^s V

t
mm
N
s
s
\ 15 mm\
-%

10
s
A
\.
= 20 mm

\
undercut f
Xj
\.
= 10 rn
SJ
m\
=

\
\
Sk
s 1

8 Sl=15 mmN. s
pbo x s

4
s
s
s
sl
X
= 10
\
mm \
\
S
sv
N
V

permis ble p^ v
\
X 1= 5 mm
\
S.

\
s
v
N

4*

s
Si = 5 mi n
s\
\\
\
\ Maximu op
Ui
5 V

\
X

2 pfo
\ \
S \

I o l^
0 5 0.8 1.0 2345 6mm8 0.5 0.8 1.0 345 6mm 8

Height of barbed leg h Height of barbed leg h

Fig. 11: Maximum permissible undercut depth Hn Fig. 13: Maximum permissible undercut depth Hmax.
for Hostaform C 9021 CV 1/30 for Hostacom G 2 N01 and M 2 N01

mm
L max. = 6%

t
P
y ^\ rr
s
x\r 30r on
10 ""

X N \ s
S N \
8 s JV s. S

6
X X ^V 1 = 20 mm \
5 X Sj=15mmS \
s
4
X \ \
Si = 10 mm
X
3
s
N^ \ V
I 2 S
I
X 5 mr n
X X
0.1 1 X s
0.5 0.8 1.0 345 6mm8 1.5 0.8 1.0 345 6mm8

Height of barbed leg h Height of barbed leg h

The undercut depth H is calculated as follows:
maximum permissible undercut depth (14)
en

, r (-!)' (>+4) J~lmax.

100
DC

12 m ^ () Dt outside diameter of the shaft [mm] in cylindrical

(-1) snap-fits or ball diameter [mm] in ball and socket
b barb width [mm]
snap-fits
1 length of hole [mm]
The maximum permissible elongation of materials with
s thickness of leg [mm]
adefinite yield point (e. g. Hostaform) should be about
Smax. maximum permissible elongation (table 1) [%]
a third of the elongation at yield stress es (fig. 15a).

For materials without a definite yield point (e. g. glass

Fig. 14: Barbed leg snap-fit supported on both fibre reinforced Hostacom, fig. 15b), the maximum per
TT
missible elongation (see table 1) should be about a third
sides; relative undercut depth j as a function of barb
of the elongation at break SR.
width and spring leg thickness for emax. = 6%

Fig. 15a: For materials with a definite yield point os

(e. g. Hostaform)
1.0
0.8

0.6

0.4
relative spring leg thickness = 0.01
y

0.2

es
3

El- 0.1

0.08

0.06 Fig. 15b: For materials without a definite yield

point os (e. g. Hostacom)
0.04

|
TB 0.02
e

0.01

0.008

0.006

IE. SR
0.004 3

0.002 Fig. 16

F
^o
ES '
0.001 /

0.3 0.4 0.5 0.6

Relative barb width -r

With cylindrical snap-fits and ball and socket snap-fits,

the maximum permissible undercut depth can be
calculated from the maximum permissible elongation
emax. (%) using the formula:
Table 1 :
Maximum permissible elongation emax. for determination of the maximum permissible undercut depth Hn

Material Maximum permissible elongation emax. (%)

Barbed
Cylindrical snap-fits,
leg ball and socket snap-fits
Hostaform C 52021
Hostaform C 27021
Hostaform C 13021
Hostaform C 13031
Hostaform C 9021
Hostaform C 2521
Hostaform C 9021 K
Hostaform C 9021 M
Hostaform C 9021 TF
Hostaform T 1020
Hostaform S 9063/S 27063

Hostaform C 9021 GV 1/30 1.5 0.8

Hostaform S 9064/S 27064 10

Hostacom M2 N02
Hostacom M2 N01
Hostacom G2 N01

Hostacom M4 N01
Hostacom G2 N02
Hostacom Ml U01

Hostacom G3 N01
1.5 1.0
Hostacom M4 U01

Impet 2600 GV 1/30 S 1.0 S 0.5

Vandar 4602 2 ^ 3.0 ^2.0

Celanex 2500 S 2.0 1.0

Celanex 2300 GV 1/30

S 1.0 S 0.5
4.2 Elastic modulus E
Fig. 17: Secant modulus Es as a function of outer fibre
The elastic modulus E0 is defined in DIN 53 457 as the elongation (based on 3-point flexural test)
(el%/min)
slope of the tangent to the stress-strain curve at the
origin (fig. 16, page 8).
a Celanex 2300 GV 1/30
b Hostaform C 9021 GV 1/30
E0 =
at the point e = 0 (15)
c Hostacom G 3 N01
d Hostacom M 4 N01
With greater elongation, e. g. Si (fig. 16), the elastic modu e Hostaform C 9021
lus is smaller because of the deviation from linearity f Celanex 2500
between a and
e. The elastic modulus then
corresponds g Hostacom M 2 N01
to slope of a secant which is drawn from the origin
the h Hostacom G 2 N01
through the e\ point of the stress strain curve. This is i Vandar4602Z
known as secant modulus Es and is dependent on the
magnitude of elongation e .

The following applies: N/mm2 ,a

7500
Es =
f(8) (16) S,

7000 V
This secant modulus ES is used in design calculations for \
snap-fits. Fig. 17 plots the secant modulus against elonga 6500
N
tion e up to the maximum permissible elongation for \\
barbed legs. 6000
r

450(f
v
4.3 Coefficient offriction fj. w
4000
\
\\
In assembling snap-fits, friction has to be overcome. The | 3500

degree of friction depends on the materials used for the \

mating elements, surface roughness and surface loading. 3000 V
Table 2 gives coefficient of friction ranges for various \
combinations of mating element materials. The friction 2500 vV
values quoted are guide values only. S3
2000
"V
Vs sf__ .!^ 1
[*-_
Table 2 ' ^^^
1500
_\ sjX ---^
- =

^ ^1\ 25*^.
Mating element materials Coefficient of friction //
1000
^S
^s
l"** *-
-

Hostaform/Hostaform 0.2 to 0.3 T

500
Hostaform/other plastics 0.2 to 0.3 1 calculation example 6.2
Hostaform/steel 0.1 to 0.2 1
0 1
Hostacom/Hostacom 0.4 3456
Hostacom/other plastics 0.3 to 0.4
Elongation E
Hostacom/steel 0.2 to 0.3

Impet/Impet 0.2 to 0.3

Impet/other plastics 0.2 to 0.3

Impet/steel 0.1 to 0.2

Vandar/Vandar 0.3 to 0.4
Vandar/other plastics 0.2 to 0.3
Vandar/steel 0.2 to 0.3
Celanex/Celanex 0.2 to 0.3
Celanex/other plastics 0.2 to 0.3
Celanex/steel 0.1 to 0.2

10
4.4 Assembly angle at and retaining angle a2
Fig. 18: Detachable joint
The assembly angle a\ (figs. 18 and 19), along with the
barb dimensions and coefficient of friction fj, between
the mating elements (table 2), determines the required
assembly force F, (fig. 20). The greater a\ the higher the
assembly force required. With a large assembly angle
(! 45) and high coefficient of friction //, it may no
longer be possible for parts to be assembled. The barb
then shears off rather than being deflected. The recom
mended assembly angle for barbed legs and cylindrical Fig. 19: Non-detachable joint for 2 = 90
snap-fits is i = 15 to 30.

With ball and socket snap-fits, the assembly angle cannot

be freely chosen. It depends on the maximum permissible
socket opening diameter DK (fig. 27).

The retaining angle 2 (figs. 18 and 19) decides how much

loading the joint can stand. The maximum load-bearing
capacity is reached when the retaining angle is a2 90 =
Fig. 20

(fig. 19). During long-term loading and/or in the event

of elevated ambient temperatures, the retaining angle 2
should always be 90. The joint is then permanent. For
detachable joints, a retaining angle 2 45 should be
=

provided, preferably a2 30 to 45.

=

F] =
assembly force required

11
 5.1 Barbed leg snap-fit
5. Design calculations
Fig. 22
for snap-fit joints
The load-bearing capacity of snap-fits under steady
(short-term) stress depends primarily on:

1 .
the mechanical properties of the plastics concerned,
particularly stiffness as expressed by the elastic

modulus ES,

2. the design of the snap-fit, i. e. wall thickness,

undercut depth H, retaining angle 2-

Load-bearing capacity is defined as the

pull-out force F2
which the joint can stand in the opposite direction to
assembly without the parts separating.

In many cases, it is possible to design the direction of The assembly force FI and pull-out force F2 (fig. 22) for
snap-fit assembly right angles to the actual loading
at barbed legs can be calculated from the formula:
direction F during service (fig. 21). Then the load-bearing
capacity of the joint is not determined by pull-out 3H ES -J // + tan Ii2
force F2 but by the break resistance or shear strength of Fl,2 =

1 1
[N] (17)
jM-tan!^
the vulnerable cross-section. This design technique is
H undercut depth [mm]
most often used with ball and socket snap-fits.
Es secant modulus [N/mm2] (Fig. 17)
J moment of inertia [mm4] (table 3)
Fig. 21 1 barbed leg length [mm]

ft coefficient of friction (table 2)

r i

2
assembly angle
retaining angle
[]
[]

The factor -^ ^
can be taken directly
'
from
l-w-tanai.2
fig. 23.

tr c V- + tan gl,2
Fig. i-i
23: Factor -r^
1 \JL tan 1,2
(from formulae 17, 22 and 25) as a function of
j assembly/retaining angle i, 2

Table 3

Barbed leg cross- Moment of inertia [mm4]

section

^\1
b'h3
i,p.
b leg width [mm]
rectangle xNSN wnere
h
|2 leg height [mm]
semicircle _j ^ 0.110 r4 r radius [mm]

third
0.0522 r4
of a circle |>_
quarter 15 30 45 60 90
^_ 0.0508 r4
of a circle Assembly/retaining angle t ,
2

12
With the retaining angle a2 90, the pull-out force F2
=

Fig. 24
is determined by the shear-stressed area and the
shear strength TB of the plastic used.

Table 4

Material Ultimate tensile

strength OR and
tensilestrength OB The shear stress TS is
[N/mm2]*

Hostaform C 52021 65
Ts =
A [N/mm2] (18)
Hostaform C 27021 64
Hostaform C 13021 65 Taking into account ultimate tensile strength OR or
Hostaform C 13031 71 tensile strength 0B (table 4), the following holds true for
Hostaform C 9021 64 shear strength
Hostaform C 2521 62
Hostaform C 9021 K 62 TB = 0.6 CTR (19)
Hostaform C 9021 M 64
Hostaform C 9021 TF 49 or TB = 0.6 OB (20)
Hostaform T 1020 64
F2max. = A TB = b c rB [N] (21)
Hostaform C 9021 GV 1/30 110

Hostaform S 27063 50
Hostaform S 9063 53
5.2 Cylindrical snap-fit
Hostaform S 27064 42
Hostaform S 9064 42
Fig. 25

Hostacom M2 N02 19
Hostacom M2 N01 33
Hostacom M4 N01 33
Hostacom G2 N01 32
Hostacom G2 N02 70
Hostacom G3 N01 80

Hostacom Ml U01 36
Hostacom M4 U01 33

Celanex 2500 65
Celanex 2300 GV 1/30 150
Celanex 2300 GV 3/30 50

Vandar 4602 Z 40

Impet 2600 GV 1/30 165

The assembly force FI and pull-out force F2 for cylin

dricalsnap-fits unlike for barbed legs can only be
- -

roughly estimated. This is because the length a (fig. 25)

which is deformed during assembly of the parts with
consequent increase in assembly force FI is unknown.
The length a depends on both the wall thickness of the
hub and the undercut depth H. A useful guide to a has
I Test specimen injection moulded according to DIN 16770 part 2. proved to be twice the width b of the moulded lip.

13
The assembly force FI and pull-out force F2 can be calcu
lated from the formula: Fig. Geometry factor
26: K as a function of diameter

ratio
Ji DG
or
DG DK
c r> ->u M+ tan 1,2 rxn
Fu-p.rt.IV2b r

f_ '
[N] (22)

p joint pressure [N/mm2]

DG outside diameter of the hub [mm]
b width of the moulded lip [mm]
fj. coefficient of friction (table 2)
ai assembly angle [] y

2 retaining angle [] J

Between undercut depth H and joint pressure p, the

s
following relationship applies: o

H 1
p =

^-Es-^ [N/mm2] (23)

DK smallest diameter of the hub [mm]

1.2 1.5

The geometry factor K depends on the dimensions of the a

Diameter ratio _ or -pj
snap-fit: L>G UK

mv + 1
VDGj Fig. 27
K= +1 (24)
fuy-i
loj
Da outside diameter of the hub [mm]
DG outside diameter of the shaft [mm]

Here it is assumed that the whole undercut depth H is

accommodated by expansion of the hub. With thin-
walled shafts, the shaft deforms as well but this can be
ignored in the case described here. Fig. 26 shows the geo
metry factor K as a function of the diameter ratio Da/Dc.

5.3 Ball and socket snap-fit

In thisdesign (fig. 27), the assembly angle j and retain

ing angle 2 and hence assembly force FI and pull-out
force F2 are the same. Table 5

The assembly/retaining angle is between 8 (e =

1%) Assembly angle a\
and 16 (e =
4%), depending on elongation.
=
-^100%
UK Retaining angle 2 DG
a

1 8 0.07
2 11.4 0.10
3 13.9 0.12
4 15.9 0.14

14
To estimate assembly or pull-out force, the formulae for The relationship between undercut depth H and joint
cylindrical snap-fits are used: pressure p can be described by the following formula (23):

+ tan
Fi =
T-.
F2 =
p n
T^2
D
a
fs~
DG
'

i
l jM-tana
T
r-Nn
[N] (25) P =

rJ'Es'T tN/mm2]

p joint [N/mm2]
pressure H undercut depth [mm]
DG ball diameter [mm] DK socket opening diameter [mm]
a f deformation length divided by the ES secant modulus [N/mm2] (fig. 17)
DG l ball diameter (table 5) K geometry factor
H coefficient of friction (table 2)
a. assembly or retaining angle [] (table 5) my + i
(26)
bJ
K= +1
fAi-
iDj 1

15
6. Calculation examples b) Assembly force FI

For the assembly force FI formula (17) applies:

6.1 Barbed leg snap-fit 3H ES J // + tani

P _

I3 \-fjL- tan 0.1

The top and bottom plates of a time switch are to be

detachably joined by two diagonally opposite spacers H = 0.3 mm

and two barbed legs. The hole diameter in the top plate ES = 2800 N/mm2 (fig. 17).
is DK 8 mm. The pull-out force F2 required per barbed
=

leg is 50 N. The barbed legs are to be injection moulded For the Hostaform/steel mating elements, it is assumed
from Hostaform C 9021 and will have a slotted circular that the friction coefficient fi 0.2 (table 2).
=

cross-section (fig. 28).

Using table 3 we obtain for the semicircular cross

Fig. 28 section:

J = 0.110 r4 = 0.11 44 = 28.2 mm4

So assembly force FI works out as

3-0.3-2800-28.2 0.2 + 0.577

F,=
153 1 -

0.2 0.577

FI = 18.5 N

Each securing element comprises two barbed

legs which
each have to be deflected by H. The assembly force per
element is therefore 2 FI = 37 N.

c) Pull-out force F2

The pull-out force F2 is calculated in the same way as

assembly force except that 2 45 is substituted for
=
a\.
a) What should the dimensions of the barbed leg be? The pull-out force is thus
b) What assembly force FI is required ?
c) What pull-out force F2 is obtained? F2 = 31.6N

a) The maximum permissible outer fibre elongation is Each element withstands a pull-out force of
chosen to be emax. 1 % For the semicircular cross-
=
2 31.6 N 63 N, which is greater than the required
section, the following applies using formula (10): pull-out force of 50 N.

H =
0.578-^-smax.
6.2 Cylindrical snap-fit
r--^-
The body of a rubber-tyred roller is to be made in two
1 is chosen be 15
to mm
parts which are permanently joined together (fig. 29).
Because of the relatively high stress involved and the fact
H = 0.578 -0.01 that the roller bears directly onto a steel axle, Hostaform
4
is used as the construction material.
H= 0.3mm

a) What should the dimensions of the snap-fit be

The diameter of the undercut is calculated from (undercut depth H) ?
DK + 2H = 8.6 mm. The slot width is chosen to be
1 mm, the b) What assembly force FI is required?
assembly angle a\ 30 and the retaining
angle a2 45. c) What is the pull-out force F2?

16
a) Maximum permissible undercut depth Hmax. b =
H
2 tan i

To determine the maximum permissible undercut depth H

Hmax., it is assumed that only the hub is deformed. 2 -tan 30
The greatest elongation takes place at the diameter DK
which is expanded during assembly to DG 16 mm. = 0.64
The maximum permissible elongation for Hostaform 2-0.577

is 6max. =
4%, according to table 1.
b = 0.55 mm

Fig. 29
The joint pressure p is calculated from formula (23).

H 1
F P"W E*-i
1

<f^
K With ^- ^r 1.5 fig. 26 shows value for K of 3.6.
1Q? a
= =

7r* ^
L>G I"
Qil 0

^: a
c
r The secant

(fig. 17) is Es
modulus for
= 1800 N/mm2.
emax. = 4% for Hostaform

3S^ \

~B So the joint pressure works out as

p-0.04.Jff
p = 20 N/mm2

The assembly force FI is

0.2 + 0.577
Fi = 20-yt-16-2 -0.55
So the maximum permissible undercut depth can be 1-0.2-0.577

calculated according to Formula (14): FI = 970.8 N

TT max.
_
p\
100
c) Pull-out force F2
~
16
100
Because the retaining angle 2 90, the joint is perma
=

Hmax. = 0.64 mm nent. The force required to separate the mating elements

can be calculated from the shear strength rB and the

DK =
DG-H shear-stressed area A (shear surface).
= 16 -

0.64

DK = 15.36 mm According to formula (20) the shear strength is

The diameter DK is chosen to be 15.4 mm. TB = 0.6 OB

b) Required assembly force FI OB = 62 N/mm2 e.g. for Hostaform C 2521 (table 4)

For the assembly force FI, formula (22) applies: TB = 0.6 62

fj, + tan ! TB = 37.2 N/mm2

F! =
p JT DG 2b
1 fj. tan !

The shear surface in this case is

The assembly angle a\ is 30. The coefficient of friction
for Hostaform/Hostaform mating elements is asumed to A = it DG b
be /A 0.2 (table 2). The width b of the undercut can be
=

=
n 16 0.55
determined from the assembly angle a\ and the undercut
depth H. A = 27.6 mm2

17
So using formula (21), the pull-put force ist: b) Assembly force FI =
pull-out force F2

F2 max.
= A TB For e = 1 %, table 5 gives a retaining angle of 2 8. =

The deformation length divided by the ball diameter is

= 27.6-37.2
~- = 0.07 according to table 5.
F2max. = 1027N

For Hostacom/Hostacom the coefficient of friction is

6.3 Ball and socket snap-fit (JL = 0.4 (table 2).

In a car, the movement of the accelerator pedal is trans D 14

For Y^r"
=
~5~~
= 1-75 for K using formula (26).
mitted via linkage
a to the carburettor. A ball and socket JLG 0

joint connecting the pedal to the linkage (fig. 30) and

made from Hostacom G 3 N 01 is required to have a my + 1
VDj
pull-out force F2 of at least 100 N. The ball diameter
K= +1
DG = 8 mm, the outside diameter Da 14 mm. =
AY.
loj
Fig. 30

( 14 V
+ 1
\7.92J
-+1
P1_Y_
\7.92j

K=2.94

According to fig. 17 the secant modulus of Hostacom

G3N01fore = l%is

Es = 4400 N/mm2.

The joint pressure can be calculated with H =

DG DK
from formula (23):

a) How large should the socket opening diameter DK be?

P=D~'Es'"K [N/mm2]
b) What assembly force F] or pull-out force F2 is
obtained? 0.1 1
4400- '
7.92 2.94

p = 18.89 N/mm2
a) Socket opening diameter DK
The assembly or pull-out force is then (formula 25):
According to table 1 the maximum permissible elon
gation for Hostacom G3 N01 is emax. 1%. =

T^-f a_
A. U +
fJ. T tan
L

Thus
^p-^D-g:-^-
fc' //tan
1
a
using formula (8)
0.4 + 0.14
= 18.89 -;r-82- 0.07-
DG ~

DK 1-0.4-0.14
e =
_

100%
DK
Fi.2 = 152 N
DG
DK =
r>

+ 1
100
6.4 Barbed leg snap-fit supported on both sides

DK =

0.01 + 1 The halves of

two housing box-shaped moulding made
a

from Hostacom M2 N01 be non-detachably joined

are to

DK = 7.92 mm barbed leg snap-fits supported on both sides (fig. 31).

by 2

18
 For an assumed spring element thickness of s = 3 mm,
Fig. 31
a spring element thickness ratio of

1
s 3
/ "T"
=

"rf
0-15 is obtained.
*-b-
1 El
p_r
f V) \\ 1 With the aid of undercut ratio of
KP k \ \ \ ,
fig. 14, an
-p
= 0.019
f ir \, l is determined.
J 1

1
1 The undercut H of the barb is then calculated from

1 u 1 H = 0.019 1

= 0.019 20

What should the dimensions of the snap-fit joints be? H 0.4 mm

The receiving holes in the moulding are 1 = 20 mm.

The maximum permissible elongation emax. according

to table 1 is

6max. = 6%
Note:
The width of the barb is assumed to be b = 8 mm. A possible flow line in the region of the spring element
This gives a barb width ratio of could provide a weak point. By increasing wall thickness
at this point, design strength can be improved (see also

C.3.4 Guidelines for the design of mouldings in engineer

--04'4
~ ~

1 20 ing plastics, p. 25, no. 18).

19
 With cylindrical snap-fits, it should be remembered that
7. Demoulding of the dimensional stiffness ofa tubular part under com

is
pression greater than under tension. The hub of a
snap-fit joints is
snap-fit (fig. 32a) generally easier to demould than the

shaft. In some parting line of the mould can

cases, the
The undercut on which the effect of the snap-fit depends run through an undercut edge, for example with a

has to be demoulded after injection moulding. The im through hole and inwardly projecting lip (fig. 32a) or
portant question here is whether the parts can be directly with an outwardly projecting lip (fig. 32b).
demoulded or whether it is necessary to bed the under
cut in slides, followers or collapsible cores. In the more frequent case of a blind hole (fig. 33), the
inner and outer faces of the undercut must be demoulded
There is no general this. The maximum per
answer to in succession. When the mould has opened (A), the
missible deformation values quoted in table 1 can of cylinder 1 is pressed out of the mould cavity by ejector 3.
course be applied equally well parts during
to demould- It takes core 2 along with it until stop 4 is reached (B).
ing. Problems usually arise from the introduction of Through further movement of the ejector, the cylinder
deformation forces into the component. These can result is stripped from the core. Expansion of the hub by an
in local stretching of the part or cause the ejector to press amount corresponding to undercut depth is not pre

into the part, among other undesirable consequences. vented (C).

A disadvantage here is that the demoulding temperature
is considerably above room temperature and hence mate

rial stiffness iscorrespondingly low.

Fig. 32 Fig. 33

plastic part
_ A

\
<

split core

\\\\\\\\\\ ^*
plastic part

20
 Photo 2 shows Hostaform fasteners which considerably
8. Applications facilitate assembly, particularly in mass production.
Nos. 1, 2 and 3 are used to fix interior trim in cars.

8.1 Barbed leg snap-fit No. 4 is a cable holder as used in washing machines and
dishwashers. No. 5 is a clip with a similar function. Here

Photo 1 shows examples of snap-fits in which the defor- the snap-fit is secured by driving a pin into the hollow
mability of the cylindrical snap-fit has been increased by shank (expanding rivet). The clips for fixing car exterior
means of slots. In the top half of the picture there are trim (no. 6) work on the same principle. No. 7 shows
two rollers with Hostaform bearings for dishwashers. the hinge fixing for a detergent dispenser tray flap on a
In the left roller, each barbed leg is deflected by washing machine.
f = 0.75 during assembly. With a barbed leg length
mm

of 1 = 7 mma barbed leg height of h

and 2.5 mm, the =

maximum elongation at the vulnerable cross-section of

the leg support point is:

f-h
=1 = 0.058 = 5.f

The lower half of the picture shows how a Hostaform

bearing bush is fixed. The bush is secured axially at one
end by a barbed leg and at the other by a flange.
Rotation of the bush is prevented by flattening off the
flange.

In all the examples shown, the assembly angle

i = 45 ,
the retaining angle 2 90 and the joints
=
are

non-detachable.

Photo 1 Photo 2

21
In photo 3 another application from the automotive Photo 5 shows that non-cylindrical housing parts can
industry is shown. This is a Hostaform plug box which also be joined by barbed
legs. This air filter intake is
snap-fits into the fascia panel. The part is made in two made from Hostacom G2 N01 In assembling the two
.

symmetrical halves which are inserted into each other. halves, the barbed legs are not deflected but the mount
ing holes are elastically deformed.
Photo 4 shows a Hostaform release lever for a car boot
lid, which is secured by two pairs of barbed legs.

Photo 3 Photo 5

22
8.2 Cylindrical snap-fit Photo 7 shows adjuster for a
an car, which is similar in
design to the previous example. It is controlled by the
Photo 6 shows pneumatic positioning device for con
a carburettor vacuum. Here, too, a rubber diaphragm is
trolling the flaps in air conditioning systems. The two secured by the snap-fit joint connecting the two halves.
Hostaform halves are snap-fitted together, thereby at the
same time forming a seal by means of an O-ring. The The assembly diameter is DG 60.8 mm and the under
=

operating pressure is 0.2 to 0.8 bar. The undercut depth cut depth H 1.6 mm. Assuming that during assembly
=

is H = 86.5 84 2.5 mm. Owing to the different wall

=
only the hub is expanded, the maximum permissible
thickness of the shaft and hub, the hub is extended more elongation is
than the shaft during assembly. The diameter difference
is apportioned between 1.56 mm expansion of the hub 1.6
e = 100% = 2.6%.
and 0.94 mm compression of the shaft.

The assembly angle is i = 45 and the retaining

angle 2 45 .
=

Photo 6 Photo 7

23
8.3 Ball and socket snap-fit 9. Explanation of symbols
Photo 8 shows parts of a carburettor linkage made from
Hostaform. The ball, with a diameter of DG 7.8 mm, =

Symbol Unit Explanation

bears in a socket with a diameter of 7.85 mm. The special
feature of this design is the socket opening which is not

circular but A mm area

elliptical. The major axis of the ellipse
corresponds to the ball diameter DG 7.8 mm, the
=
a mm deformation length (ball and
minor axis is 7.5 mm in length. In this direction, the dia socket snap-fit
meter difference is b barb width
mm (barbed leg snap-fit
supported on both sides)
H = 7.8 -

7.5 mm = 0.3 mm
Da mm outside diameter of hub

Assuming that this diameter difference is

spread evenly Dr mm largest diameter of the shaft
around the circumference, during assembly the parts will (cylindrical snap-fit)
be expanded by mm ball diameter (ball and socket
snap-fit)
0.3
e = 100 = 2%. DK mm smallest diameter of the hub
2-7.5
(cylindrical snap-fit)
mm socket diameter (ball and socket
snap-fit)
Es N/mm2 secant modulus (fig. 17)
F, N assembly force

F2 N pull-out force

h mm barbed leg height

H mm undercut depth
J~Mnax. mm maximum permissible undercut
Photo 8
depth
mnr moment of inertia (table 3)
geometry factor (fig. 26)
mm difference between outside edge
of leg and inside edge of hole

mm barbed leg length

mm length of receiving hole
(barbed leg snap-fit supported
on both sides)

H J_
N/mm2 joint pressure p =
^= Es
K

mm wall thickness
o
assembly angle
o
retaining angle
% elongation
% maximum permissible elongation
%/min rate of elongation
coefficient of friction (table 2)
N/mm2 tensile strength (table 4)
N/mm2 ultimate tensile strength (table 4)
N/mm2 shear strength

24
10. Literature
Engineering plastics
Design Calculations Applications
[1] H. Schmidt: Fgen durch Schnappverbindungen,
VDI-Z, No. 5, 1972 Publications so far in this series:
[2] K. Oberbach, D. Schauf: Schnappverbindungen
aus Kunststoff, Verbindungstechnik, Nos. 6, 7 A. Engineering plastics
and 8, 1977 A. 1.1 Grades and properties -
Hostaform
[3] W. W. Chow: Snap-fit design concepts. A. 1.2 Grades and properties -
Hostacom
Modern Plastics International, August 1977 A. 1.4 Grades and properties -
Hostalen GUR
A. 1.5 Grades and properties -

Celanex,
Vandar, Impet
A.2.1 Calculation principles
A.2.2 Hostaform -
Characteristic values and
calculation examples
A.2.3 Hostacom -
Characteristic values and
calculation examples

B. Design of technical mouldings

B.I.I Spur gears with gearwheels made from
Hostaform, Celanex and Hostalen GUR
B.2.2 Worm gears with worm wheels made from
Hostaform
B.3.1 Design calculations for snap-fit joints in
plastic parts
B.3.2 Fastening with metal screws
B.3.3 Plastic parts with integrally moulded threads
B.3.4 Design calculations for press-fit joints
B.3.5 Integral hinges in engineering plastics
B.3.7 Ultrasonic welding and assembly of
engineering plastics

C. Production of technical mouldings

C.2.1 Hot runner system Indirectly heated,
-

thermally conductive torpedo

C.2.2 Hot runner system Indirectly heated,
-

thermally conductive torpedo

Design principles and examples of moulds
for processing Hostaform
C.3.1 Machining Hostaform
C.3.3 Design of mouldings made from
engineering plastics
C.3.4 Guidelines for the design of mouldings
in engineering plastics
C.3.5 Outsert moulding with Hostaform

25
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