Avient helped the customer calculate costs for the 12-month period. Projections showed the cost of a new tool would be recouped within months, enabling the manufacturer to move forward with confidence. Even after the cost of the new tooling, the company will save about $72,000 the first year, an impressive and rapid return on the investment in new tooling.

The design team had two objectives: improve vibration damping performance of the boot to deliver a better user experience, and streamline manufacturing of the part to reduce system costs. The company foresaw that integrating this step into the molding process for the saw housing would cut assembly time and overall costs.  Avient gathered detailed data from this customer’s production facility in Mexico and helped them calculate and compare the costs of the two solutions.

That saved the company $70,000 a year in direct manufacturing costs. Reduced freight costs: The lower specific gravity of TPEs versus thermoset silicone rubber cut the overall part weight by 20 percent. That reduced associated freight costs by $36,000 a year.

Cost of sales Cost of sales: Restructuring costs

Cost of sales Cost of sales: Debt financing costs

Cost of sales Cost of sales: Debt financing costs

Cost of sales Cost of sales: Debt financing costs

Cost of sales Cost of sales:    Restructuring Costs

Paint adds a great surface finish to automobile parts, but painting always adds cost, time, and additional logistics requirements. Suitable for standard injection molding machinery, Smartbatch FX reduces the cost per part by 30 percent or more compared to painted parts. This recent project is a significant step forward in reducing the cost to manufacture highly visible interior applications.”

This approach maintained the streamlined design while controlling costs. Cost savings: Molding the bumpers separately and inserting them into the housing keeps costs down yet provides the seamless appearance of overmolding. Creating a two cavity tool for the bumpers saved PTA 70% over the cost of an overmolding tool, and reduced scrap rates typical with overmolded housings by 80%.