Metal To Plastic Conversion

FacFox is an industry leader with years of experience partnering with OEMs to improve their products, reduce costs and streamline the manufacturing process by converting metal components and assemblies to plastic.

Metal to plastic conversions focus on improving the product or component integrity while reducing overall weight and cost.

A key to success is the continual introduction and improvement of engineered plastic resins that have the strength and durability to compete with metal. In addition, these plastic materials can provide better wear surfaces and have lower friction. For example, metal bearings can be eliminated by designing bearing features directly into the plastic part.

Plastic components are often superior when it comes to high-impact strength, fatigue life or recoverable deformation, and plastic parts can be molded into complex shapes at a much lower cost than machining metal components.

In addition to part weight reduction, consistent dimensions and lower cost, metal to plastic conversions often result in enhanced performance and product value.

Improve Products

• Designs consolidate parts and create additional performance features
• Ability for more complex shapes and geometries
• Opportunity to combine materials for enhanced features using multi-shot molding, overmolding or insert molding
• Increased strength and durability
  
• Enhanced decoration or labeling with in-mold decorating and labeling
• Improved aesthetics
• Ability to maintain close tolerances
• Plastic materials and construction absorb impact and reduce noise
• Lighter weight components for improved product performance

Reduce Costs

• Reduced secondary operations, such as painting, machining or assembly
• Improved production consistency
• Reduced part/product weight – reduced shipping and operating costs
• Product improvements resulting in increased customer satisfaction and decreased warranty issues
• Streamlined manufacturing cost savings
• Reduced scrap and waste
• Part consolidation

Streamline Manufacturing

• Reduced labor and time, eliminating secondary operations and assembly
  
• Plastic injection molding is a faster and more consistent manufacturing process than metal fabrication
• Tools for testing materials and performance in the design phase predict performance