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This article describes the field o ergonomics and explains how its integration into the product development process can lead to customer satisfaction and increased profits for the manufacturer. This article discusses such issues as cost advantages and environmental compliance to explain current trends and offer predictions for the future. So This case study of an injection molded polycarbonate power pack housing for a medical device highlights the role of stress analysis in pinpointing the cause of failure. In addition to explaining observed failure characteristics of the housing, the stress analysis helped in validating its design and material selection. In order to encourage end-users to consider more than one thermoset when designing a product, the author provides an overview of this class of plastics.