From sheet metal to plastic: housings 70% lighter and 30% cheaper, in a series of 25 units
The customer's challenge
An industrial machinery manufacturer needed to manufacture the fairing housings for its concrete vibrating machine.
Until then, these parts were made in folded sheet metal, but this solution created multiple problems: the housing geometry was complex and difficult to execute in sheet metal, the finish required an additional painting process, and the machine’s own vibration was transmitted to the metal producing excessive noise.
Critical factor: the series was very short —barely 25 units-, which made assuming the costs of conventional tooling unviable.
CTE's solution
CTE proposed replacing the sheet metal with thermoformed parts in ABS + ASA of 6 mm, a material that combines high mechanical strength with an excellent surface finish.
To suit the short series, a very low-cost DM mold was designed, in which the two parts of the assembly were also integrated, simplifying both the tooling and the production process.
The result: a solution 30% more economical than sheet metal and delivered in just 4 weeks.
-30%
vs. sheet metal solution
4 wks.
delivery lead time
25 units
viable series
Advantages delivered
01
Much lighter: from ~ 12 kg in sheet metal to ~3.5 kg in plastic, a weight reduction close to 70 %.
02
Aesthetic finish direct from mold, completely eliminating the painting process.
03
No vibration noise: plastic dampens where metal resonated.
04
Two parts in a single mold: tooling and assembly simplified by integrating the assembly.
05
No corrosion and recyclable: the inherent advantages of technical plastic.
Let's talk
Tell us what you need. Within 48 hours we give you technical guidance and a no-obligation quote.