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PROGRESSIVE IS IMPRESSIVE: "How Elrae's Progressive Die Stamping Technology Improved Production & Efficiencies."
Problem:
A plastics job shop injection molder and leading supplier to the automotive and recreational markets developed a tension bar for an automotive door application.
The part’s initial design called for a die cast molded metal part with close tolerances. The part would then be injected molded to form the final plastic assembly. The part incorporated an extrusion-like shape made from a high strength/low alloy material. The hole tolerance and wall thickness in the part’s extruded neck portion were especially critical to ensure proper bearing fit in the final door assembly.
Traditionally, the design criteria of such a part is common to die cast methodology. Since the cost of procuring the die cast part was high, the customer hoped they could find a lower cost, more efficient alternative. And given the part’s volume requirements, a faster production method was preferred.
Solution:
Elrae’s Early Supplier Involvement team, drawing on their vast experience, felt the part could be extruded and sized using progressive die stamping technology.
After testing the theory with prototypes, Elrae determined this part could in fact be made progressively and presented the new method to the customer.
After the customer accepted the concept, Elrae developed a progressive die that met the customer’s requirements. Also, Elrae was able to effectively create the hole extrusion using high strength/low alloy material.
Results:
Improved Production: Progressive die technology increased production efficiencies to better meet demand and customer JIT delivery schedules.
Consistent Quality: Progressive tooling allowed consistent quality and repeatability across all components vs. multi-cavity die cast operations that could cause component variation.
Lower Costs: The higher speed production resulted in lower per-piece price and ultimate cost savings to Elrae’s customer.
Market Expansion: Elrae’s alternative process was so successful, the customer used this technology on four more parts – enabling him to expand his product line to a larger market segment
