Part: Tiger Latch Handle
A global automotive supplier approached New Berlin Plastics when it needed an innovative manufacturing solution. The Tiger Latch Handle was destined for a major marine engine manufacturer, therefore our customer required a molder that had experience producing paint-ready surfaces and could quickly move the design from concept to production. Our customer-focused team transformed the initial design. In the end, New Berlin Plastics delivered a robust, clever, and economical design.
Throughout this project New Berlin Plastics:
- Created and managed a complicated, but efficient, supply chain
- Applied innovative manufacturing processes, designing the part for a vertical loader to stabilize the insert during injection molding
- Streamlined part and insert design
The Tiger Latch Handle presented our team with challenging design and cosmetic requirements. The first manufacturing problem was how to attach a quarter pound mass to the back of the part to act as a counterweight. The original concept secured the insert post-molding leaving it exposed to the elements. This required additional labor and a costly stainless steel insert (necessary to meet salt spray requirements). Our team redesigned the part to completely encapsulate a cost effective sintered metal insert during the molding operation using a progressive over molded process, thus eliminating the need for a more expensive option and eliminating the need for corrosion resistance and validation testing.
By assisting with redesigning the handle and insert, New Berlin Plastics was able to improve performance and cut costs for our customer.
Speed to Market:
Innovative engineering reduced the number of steps between manufacturing and distribution allowing New Berlin Plastics to cut the lead time for our customer. We also created and managed a complicated supply chain in order to source inserts for production, third parties for painting and decal work, and distribution to our customer.