SOLIDWORKS Design & Help

Hello engineers,

I am currently developing a Type 2 electric vehicle charging plug in accordance with the IEC 62196-2 standard. My responsibility in this project is to design the handle/grip section where the cable connects to the plug — completely from scratch.

My goal is to achieve an ergonomic, durable, and injection-molding-friendly design optimized for both user comfort and manufacturing.

I would greatly appreciate feedback, ideas, or reference examples on the following topics:

• Ergonomic grip geometry and hand-fit considerations
• Recommended wall thicknesses and rib structures
• Proper mold parting line and gate location
• Reinforcement strategies for cable strain-relief and PCB routing
• Sealing approaches for achieving a higher IP rating
• Critical points regarding mechanical and thermal loads

Any input from those with experience in EV connectors, plastic housings, or ergonomic product design would be extremely valuable.

Thank you in advance!

I added another drawing that i took from here for example.