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Window Frame Product Line – Design for Injection Molding
Develop an injection moldable solution to problematic, extruded product line with high scrap rates.
Our customer’s product line was a high-end offering to their customer base that demanded high quality. This product was both aesthetic and functional, adding to the beauty of the customers home and keeping rain and weather out. The product was assembled from a co-extrusion that was mitered and glued together. To achieve the level of quality that was consistent with this being a high-end product required a pain staking assembly process that resulted in a very high scrap rate. The performance of the product was also problematic with the seal not performing consistently causing numerous customer complaints and warranty claims.
Working closely with our customer’s engineering and marketing teams, Accudyn’s engineers helped develop a product design that met all the customer requirements. We also developed both a tooling and manufacturing strategy in conjunction with the part design to ensure we could meet their requirements consistently in a production environment and minimize their tooling investment.
The resulting improvements to this product line for our customer have been a complete success. The performance issues related to the co-extruded manufacturing process have been eliminated completely and visually, the injection molded product is a clear improvement that the customer’s marketing department predicts will increase their sales.
One more thing, it costs less too!
Making a dramatic change to a key product including the entire manufacturing process is challenging and not without risk. Partnering with Accudyn on these difficult projects ensures that all the details will be considered and addressed.