Designing for Toughness: How to Specify & Achieve the Right IK Rating
It's episode 300! Host Adrian and Sofeast head of NPD Paul Adams dig into IK ratings, what they measure (impact energy in joules), why they matter for real-world product abuse (drops, kicks, tool strikes), and how to connect use-case, environment, materials, and system-level design choices (wall thickness, ribs, radii, gate location) to hit targets like IK06–IK10.
You’ll hear practical examples (from light switches to job-site drills), polymer options (PP, HIPS, ABS, PC/ABS blends), and environment trade-offs (temperature, UV, chemicals, cost) so your spec says more than “make it rugged.”
Episode Sections:
00:12 – Introduction: designing for toughness via IK rating
01:58 – IK vs IP: ingress ≠ impact toughness
05:16 – What is IK? Impact energy (J); Izod/Charpy context
08:33 – IK scale overview: IK00 → IK10 (~20 J)
09:18 – Start with real-world use before materials
10:15 – Low-impact examples (e.g., light switches)
11:56 – Mid-impact examples (bench drops, tools falling)
12:50 – High-impact / IK10: sledgehammer territory
14:02 – Specify toughness explicitly: choose an IK level
17:02 – Mapping joules to IK (≈0.35 J to 20 J)
19:34 – Materials at IK06 (~1 J): PP, HIPS, ABS, PA
21:47 – Materials at IK09 (~10 J): high-impact ABS, PC/ABS, modified PA
25:51 – Designing for IK: thickness, ribs, radii
27:18 – Molding realities: gate location, weld lines
29:26 – Environment trade-offs: temperature, UV, chemicals, cost
33:14 – Same IK, different designs: oil vs building site
35:16 – Key takeaway: IK is a system rating
35:40 – Wrapping up
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