RL HUDSON SUCCESS STORIES

REDESIGNING A COMPLEX PART

A Customer Improves a Part and Reduces Costs by Collaborating with RL Hudson’s Product Design Team.

THE CHALLENGE

The customer’s original design for the intake silencer / plenum was intended to be injection molded in two pieces, and hot plate welded together. A complex parting line would have made welding difficult. This would have led to lots of scrap and additional control steps to ensure consistent quality. In addition, the details in the lower half created drastically varying wall sections, which would have created molding problems. All of these things combined would, of course, have driven up the part cost.

THE SOLUTION

Working closely with our customer, we redesigned the component to be one blow molded plenum with an injection molded mounting flange hot plate welded on (as shown above, center and right). In the process, we also simplified the sensor arrangement on the end of the part.

The assembly had virtually no start-up issues and worked from the outset. The design even afforded flexibility to easily make further product enhancements after initial tooling. Making this change reduced injection mold and hot plate weld tooling expenses and quality-related costs.