<![CDATA[Snap-fit joints are widely used in industry due to the fast and simple assembly process they enable; however, selecting the appropriate materials and dimensions is crucial for achieving optimal locking strength and structural integrity. This study aims to determine the combination of material, snap-fit arm thickness, and cantilever length that yields optimal performance for a snap-fit joint in a motorcycle luggage application. The research employed Finite Element Analysis (FEA) simulations using SolidWorks Simulation and Design of Experiments (DoE) to evaluate the influence of these three parameters on locking force, maximum stress, deformation, and the factor of safety. Simulation results indicate that ABS withstood the highest locking force of 46.2 N, with a simulated stress of 5.0 MPa and a deformation of 4.7 mm. PP exhibited the lowest deformation (1.62 mm) at a force of 32.6 N, while HDPE produced the lowest stress at a force of 21.7 N. Based on considerations of locking strength and structural integrity under heavy load conditions, ABS was identified as the best material. Optimization results show that ABS provides a 23% increase in strength compared to the other material alternatives. These findings demonstrate that material selection must balance load-bearing capacity and deformation response to achieve an optimal snap-fit design.]]>
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