Challenge
Premetec was presented with a significant challenge: a part that had historically been manufactured from a plastic round bar through machining. However, this method encountered numerous issues and inefficiencies. The challenge was to find a solution that would streamline production, reduce costs, and enhance quality. The requirement was to produce a few thousand parts annually, each meeting stringent alloy and strength specifications. Traditional 3D-printing was not a viable option due to these specific requirements.
Insight
Injection mold innovation: Premetec devised a groundbreaking solution by manufacturing an injection mold to create the part. This transformative step replaced the traditional round bar machined part with an injection-molded counterpart.
Precision machining: While injection molding handled the bulk of the part’s formation, precision machining was still necessary to achieve features and dimensions that were not possible to mold accurately.
Material expertise: The choice of material was critical to meet the special alloy and strength requirements. Premetec’s material experts selected the ideal plastic material that met these specifications.
Final assembly: The assembly process integrated the newly molded plastic part with essential components such as seals and springs, ensuring a complete and functional assembly.
Results
Premetec’s commitment to innovation and problem-solving attitude delivered remarkable results:
Streamlined production: The transition from machining to injection molding significantly streamlined the production process, reducing lead times and costs.
Quality enhancement: The new production method, coupled with precision machining, ensured that the final parts met the highest quality standards and dimensional accuracy.
Cost savings: The innovative approach resulted in cost savings for the customer, making the production process more cost-effective and efficient.
Material compliance: The choice of the right plastic material met the special alloy and strength requirements, ensuring the parts’ performance in their intended applications.
Client satisfaction: Our client received parts that not only met their stringent requirements but also provided cost savings and quality assurance. This project reinforced the partnership between Premetec and the client, underscoring our commitment to excellence in industrial manufacturing.
In conclusion, this case study illustrates Premetec’s ability to innovate and optimize production methods to achieve cost savings, enhance quality, and meet specific material requirements. Our innovative approach to precision engineering and efficiency empowers us to redefine what’s possible in precision manufacturing, offering solutions that elevate industry standards.