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Due to nature of how the material flows and forms, sharp corners usually result in blow holes and porosity in the corners. Adding a generous radius improves the molding of corners and distributes the stress over a broader area adding to the product’s strength. The minimum recommended angle at the corner of a part for polyethylene and PVC is 30, nylon is 20, polycarbonate is 45.

Corner angles less than these amounts can result in a bridging of plastic, increased porosity and excessive shrinkage.