Joining of Plastics: Handbook for Designers and Engineers.

We were actually looking for a book on resin selection for engineers and designers when we ran across this one. It does, in fact, have an excellent section on resins, 34 of them to be exact. But its exhaustive coverage of other aspects of plastic design, including 22 processing methods and 15 methods for joining plastics, make it an excellent all-around choice for both casual and full-time professionals working with plastics.

The preface points out that it is "more complicated to design with plastics than with metals," yet the book is designed to allow easy access to a rich store of valuable information. For instance, in Section 5.4.1 the author lists key properties for each generic resin group. Acetal, for example, boats very high tensile strength, toughness, stiffness and dimensional stability, high abrasion resistance, and resistance to chemicals and creep under load. Section 5.4.3. provides SPI tables for each resin, including both fixed and variable tolerances. Tolerances listed as "commercial" in the tables are approximately what can achieved via Rapid Injection Molding. This chapter also addresses applications, assembly methods, and weldability for each of the plastics.

The discussion of joining plastics begins with the very first chapter. Here you'll find an overview of assembly methods, specifically addressing strengths and limitations, typical applications, and processing methods. From here the reader is directed to other sections of the book where specific issues are addressed in more detail.

As suggested by the title, it is methods of joining that get the author's closest attention. Chapters two through four address design for efficient assembly, cost reduction in assembly, and design for disassembly and recycling. Chapters five and six cover matching assembly method to material and production process, respectively. Chapters seven and eight cover adhesive and solvent joining (including issues such as surface energy treatments to make olefins glueable) and fasteners and inserts (both molded-in and post-processed). Chapter nine focuses on hinges.

Seven chapters of the book are devoted to welding methods including fusion and resistance welding, hot gas welding, induction welding, spin welding, ultrasonic welding, vibration welding, and laser welding. Other chapters address a variety of fits--force, shrink, snap, and more including issues of stress prevention--tapped and molded threads, and miscellaneous forming methods.

All in all, this is an encyclopedic work that takes an enormous amount of information and makes is readily accessible for either study or reference. It is well illustrated and well supplied with charts and tables that simplify complex data. And, finally, for those who plan to actually make parts, it provides detailed information on material suppliers and equipment manufacturers.

Kevin Crystal, Protomold Senior Quality Engineer, Maple Plain, MN