| Underhood temperature | Commonly specified from about −40 °C to 125 °C, which rules out most standard polymers | PA66 at about 90 °C heat deflection and ABS at 98 °C at 0.45 MPa are both marginal |
| Polymer selection | Glass-filled PA66 at roughly 180 MPa tensile and 9 GPa modulus, or PEI at about 200 °C heat deflection where temperature governs | The temperature stated before the resin is chosen |
| Interior polymers | PC-ABS at 55 to 60 MPa with a heat-deflection figure around 100 to 115 °C, chosen for impact and processability | Whether UV exposure requires a stabilised grade |
| Structural metals | 6061-T6 at 276 MPa / 40 ksi yield for brackets; 4140 from 415 MPa annealed to roughly 1520 MPa quenched and tempered for loaded components | Whether the part is strength-limited or stiffness-limited |
| Corrosion protection | Zinc plating at 5 to 25 µm plus a chromate, reaching 96 hours and beyond to ASTM B117 with a yellow chromate | Salt-spray hours are a comparative test, not a service-life prediction |
| Capability expectation | Critical characteristics commonly carry a Cpk target of 1.33 with a stated measurement method | A capability target implies a sampling plan, not one measured part |
| Tolerance practice | ±0.125 mm standard, ±0.025 mm on named critical features | Which few features carry the function |
| Prototype to production gap | A machined sample cannot validate a moulded component: shrinkage from 0.5% for ABS to 2.5% for acetal, knit lines and fibre orientation exist only in moulding | Which conclusions the prototype supports |
| Tooling lead time | Production injection tooling commonly 8 to 16 weeks to first samples; aluminium prototype tooling 2 to 4 weeks | Where tooling sits in the programme schedule |
| Volume effect | Cavity count, cycle time and press tonnage follow annual volume rather than preference | The forecast stated as a forecast, distinguished from firm orders |
| Submission documents | Programme-level approval packages are a customer requirement on the supplier, negotiated per programme | Not automatically included in a component quote |
| Traceability | Material certificates, lot boundaries and part identity stated as separate requirements | Where the lot boundary sits, and how parts are identified |