By converting a cast aluminum filter housing to plastic, we helped a heavy machinery manufacturer lower capital costs for tooling, reduce product weight and cost, and improve ROI.
Our client wanted to improve performance and reduce the costs associated with producing a cast aluminum filter housing, which held a filter cartridge and magnet to clean metal fragments from engine lubricants.
We conducted a thorough design review, investigating various thermoplastic materials and processes, and ultimately recommended powdered metal inserts to withstand torque, vibration and fastener loads. We molded these inserts into the plastic filter housing during the injection molding process to keep costs to a minimum. We also added a twist lock cover to help prevent failures with threads and eliminate the need for complex tooling. That resulted in a lower initial capital cost for tooling and an improved return on investment.
- Cost and weight reductions. Using highly engineered plastics to replace cast aluminum reduced weight by 66% and cut overall production costs.
- Fewer production processes. Our corrosion-proof design process eliminated the need to paint the filter housing, also reducing cost.
- Faster time to market. By switching from cast aluminum to plastics, we were able to produce one component approximately every 100 seconds, a significant decrease over the original process.
Clients across industries are discovering the benefits of converting from metal-to-plastic. At IVP Plastics, we’ve helped automotive, heavy equipment and industrial manufacturers realize cost savings from 30% to 60%—without sacrificing performance. Talk to us if you’re looking to:
- Reduce product weight, cost and total number of components
- Streamline production processes and speed time to market
- Take advantage of materials more resistant to high temperatures, chemicals or chemical reactions and electrical conductivity
- Eliminate contact with heavy or potentially corrosive metals