Engineer Education Series #7: Designing Plastic Components for Outdoor Equipment

Outdoor equipment components are exposed to some of the most demanding operating environments. Unlike controlled indoor applications, outdoor components must withstand prolonged exposure to sunlight, temperature fluctuations, moisture, and physical impact.

Designing plastic components for these conditions requires careful consideration of material selection, geometry, and long-term durability. When these factors are addressed early in the design process, plastic components can provide reliable performance and extended service life in outdoor applications.

UV Exposure and Material Degradation

One of the most significant challenges for outdoor plastic components is ultraviolet (UV) radiation from sunlight.

Over time, UV exposure can cause:

• discoloration or fading
• surface cracking
• embrittlement
• reduced mechanical strength

To mitigate these effects, engineers should select materials with built-in UV resistance or incorporate UV stabilizers and additives.

In many cases, co-extrusion can also be used to apply a UV-resistant outer layer while maintaining core material performance.

Temperature Fluctuations and Thermal Expansion

Outdoor environments often involve wide temperature swings, from extreme cold to high heat.

These fluctuations can cause:

• thermal expansion and contraction
• dimensional changes
• potential warping or distortion

Design considerations include:

• allowing for expansion gaps where necessary
• selecting materials that maintain flexibility at low temperatures
• ensuring the material can withstand peak temperature exposure

Understanding how the material behaves across the expected temperature range is critical for long-term performance.

Moisture and Environmental Exposure

Outdoor components are frequently exposed to moisture, humidity, and environmental contaminants.

This can include:

• rain and standing water
• freeze-thaw cycles
• chemicals such as fertilizers, oils, or road salts

Plastic materials generally offer strong resistance to corrosion compared to metal, but not all plastics perform equally in these conditions.

Material selection should account for:

• water absorption rates
• chemical resistance
• long-term environmental durability

Impact Resistance and Mechanical Stress

Outdoor equipment components often experience physical impact, vibration, and mechanical stress during use.

Designing for impact resistance is critical in applications such as:

• agricultural equipment
• construction machinery
• infrastructure protection systems

Materials should be selected for:

• toughness
• flexibility under load
• resistance to cracking in cold temperatures

In addition, avoiding sharp corners and incorporating radii can help reduce stress concentrations.

Designing for Long-Term Durability

Successful outdoor components typically incorporate several key design principles:

• UV-resistant materials or additives
• consistent wall thickness
• smooth geometric transitions
• rounded corners to reduce stress points
• allowance for thermal expansion

These considerations help ensure components maintain performance over time, even in harsh conditions.

Working with OEM Engineers

Lincoln Plastics works with OEM manufacturers to produce plastic components designed for outdoor environments, including:

• agricultural equipment
• infrastructure protection systems
• industrial machinery
• cord management products

If you're designing a plastic component for outdoor use and want to evaluate material or design considerations, our team is available to help.

Engineer Education Series

Explore the full series:

Engineer Education Series #1:
Designing Plastic Extrusion Profiles – Key Engineering Considerations

Engineer Education Series #2:
Plastic Extrusion Tolerances – What Engineers Should Expect

Engineer Education Series #3:
Common Design Mistakes Engineers Make with Plastic Extrusion

Engineer Education Series #4:
How Plastic Extrusion Tooling Works

Engineer Education Series #5:
Plastic Extrusion vs Injection Molding – When to Use Each

Engineer Education Series #6:
Plastic vs Metal Components in Equipment Design

Engineer Education Series #7: Designing Plastic Components for Outdoor Equipment
Engineer Education Series #8: Co-Extrusion vs Single Material Extrusion
Engineer Education Series #9: How Engineers Collaborate with Extrusion Manufacturers
Engineer Education Series #10: Material Selection for Extruded Plastic Parts

Additional Engineering Resources

Engineers designing for outdoor environments may find the following resources helpful:

Society of Plastics Engineers (SPE)
https://www.4spe.org

Plastics Technology – Weathering and UV Resistance
https://www.ptonline.com

UL Prospector – Material Data and Environmental Properties
https://www.ulprospector.com

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