Lightweighting continues to remain a top priority for automotive manufacturers in order to help them meet strict fuel-efficiency requirements or to help get them one step closer towards getting the most mileage out EVs battery.  One way tiered suppliers are going about this is by redesigning traditional metal clamps with well designed injection-molded clips and fasteners.

Design engineering a plastic part to replace without compromising performance equires expertise in design, material, tooling, injection molding, and validation testing.  In this post, we’re going to explore some of the designs that have become the go-to for tier-1s and OEMs over the years.

Designs to Choose From

There is a vast library of different fastening clip designs automotive manufacturers can implement and optimize. Many of these designs include small, intricate features (such as the tree, hand-grip, and rib-cage designs) that are all subject to flashing and packing issues.  Without proper setup and precision tooling, these issues can lead to performance failures

Ultimately, it comes down to design.  Improper spacing between features, not enough material, too much material in some spots, etc. … all lead to parts that down operate or cannot be manufactured.

Below we’ve listed out some of the most common designs and what they’re typically used for. Each one has its pros and cons.

Tree Insertion Design

Tree insertion designs on fasteners and clips have long been used for body panel attachments of all kinds. It is well-known to be a strong design, capable of higher removal forces. An injection molder needs to work diligently to minimize insertion forces without compromising on retention capability.

The intricate features of the tree design require special attention to the spacing between features and areas where there may not be enough material vs. areas with too much material.

x-mas-tree-500x500


Butterfly Tab Design

Typically installed into panel holes, the ‘Butterfly Tab’ design is an Echo favorite.

This design is perfect for hard-to-reach places and areas requiring minimal insertion forces during the final installation. We don’t recommend this design for fasteners holding multiple, large lines. A tree design has higher retention.

butterfly-design-500x500


Latch Design

A clip with the lid/latch and living hinge design is a very common method of retaining lines.  Latch designs make insertion easy, yet provides a reliable, strong hold. Adding multiple latches to a fastener is recommended when a fastener holds multiple lines.

latch-design-500x500


Hand-Grip Design

This style of fastener installs onto a stud (screw). The design features great reliability ensuring low installation forces., but it’s a less attractive option for tight space though due to its larger profile.

Automotive clip design


Rib Cage Grip Design

Rib cage-style fasteners install onto a stud (screw). This design sometimes has larger insertion forces than the hand-grips design (above) but has a smaller profile than the hand-grips, making it a better option for tight areas.

Automotive fastener molder


Rabbit Ear Design

Lines install into this. Best for small diameter lines. Great for small areas.

When a fluid routing line is inserted into this type of fastening device, the rabbit ear flap area flexes down, allowing for easier insertion, and then spring back into place in order to retain the line.

bunny ear clip design


Wedge Clip Design

Fluid routing lines install into this design. It’s best for packaging small diameter lines together in bundles. Not as good for retention at the vehicle-level.

fastening-wedge-design-500x500


Wedge Clip with TPE Insert Design

This design includes an over-molded TPE material that helps with reducing NVH, and limits both rotation and translation of the lines. The wedge type design makes this clip a simple assembly, yet it also provides reliable retention once the line is inserted.

 

wedge clip with tpe for metal lines


TPE Grip

Commonly used in a lid-latch configuration. The TPE grip is great for reducing NVH, and limiting both rotation and translation. This design has higher retention forces than the Rabbit Ears w/ Grip, but it’s a little more complicated to assemble.

TPE Grip on clip

 


Conclusion

Overall, while these are some of the most popular and effective fastening designs being used in automotive applications, the rise of EVs and Hydrogen Fuel Cell vehicles continue to disrupt the industry.  We’re far from over with optimizing and rethinking the way plastic is used throughout a vehicle.

To see Echo & Ammex’s Design Innovations for yourself, head over to our Contact Us form to schedule time with our team.