Metal Replacement

Case History 2


The customer's request

Substitution of the current flange with an equal plastic component.

Project goals:
> 50% reduction of the component cost
> 50% reduction of the production lead time
> 40% reduction of the component weight

The challenge

Redesigning a component subjected to strong mechanical stress;
Realization of the component in a single production phase;
Reviewing the geometry and making the component stackable to optimize the packaging.

The solution

Component re-engineering and functional control by FEM analysis;
Use of a carbon-reinforced technopolymer;
Integration of threaded inserts by overmoulding process;
Simple mould with recovery and reuse of the sprue on the production line.

The results