In the dynamic plastic injection sector, the search for solutions that combine efficiency, robustness, and customisation is constant. This article explores an exemplary case study from ETMA, where innovation and adaptability were crucial to developing a compression limiter optimised for overmoulding.
Join us on this journey, from the prototyping phase to series production, and discover how ETMA’s integrated approach translates into competitive advantages for its clients, with a focus on the excellence required by the automotive sector.
THE INITIAL CHALLENGE: COMPRESSION LIMITERS FOR PLASTIC INJECTION
A client specialising in the plastic injection industry, whose project was ultimately destined for the demanding automotive sector, presented ETMA with the need to develop and produce compression limiters. These metallic components (inserts) are vital for protecting plastic parts against excessive compression loads during assembly and tightening, ensuring that the polymer does not crack and guaranteeing the functional integrity of the final assembly.
The central challenge was to find a production route that guaranteed the sealing and dimensional precision required for the overmoulding process, while simultaneously being scalable for series production of approximately 300,000 parts annually. Initially, prototype production by turning allowed for concept validation, but the high cycle time made it uncompetitive for large volumes. On the other hand, initial attempts at cold forging revealed technical difficulties with the specific geometry of the part, demanding a more creative and flexible solution from ETMA.
ETMA’S INNOVATIVE APPROACH: HYBRID SOLUTION AND CO-ENGINEERING
It is at this point that ETMA’s flexibility and co-engineering capabilities stand out. Instead of limiting itself to a single process, ETMA’s technical team developed an innovative hybrid solution, combining the best of two worlds:
- Turning: Used for the initial shaping phase of the part, ensuring the necessary dimensional precision.
- Stamping: Applied in a second operation to deform (ovalise) the part, achieving the desired final geometry more efficiently.
This approach not only overcame the technical difficulties encountered in cold forging but also allowed for significant optimisation of production time and costs, making the solution competitive for series production. This project demonstrated ETMA’s creativity and continuous internal learning, paving the way for new types of parts with similar requirements.
ETMA’S INTEGRATED PRODUCTION PROCESSES IN ACTION
One of ETMA’s great advantages lies in its unique system of 10 Integrated Production Processes. This internal capability allows for total control over all project phases, from concept to final delivery. In this case study, the following processes were mobilised:
- Prototypes – Initial development and validation of the part with the client, ensuring that the design and functionality meet the requirements.
- Turning – Production of the initial round shape of the steel compression limiter, using multi-spindle lathes, ensuring the necessary precision for subsequent phases
- Stamping – Deformation and ovalisation of the turned part, using presses, giving it the final geometry efficiently and controllably.
- Tools – Design and manufacture of the specific tool for the stamping operation, crucial for part forming.
- Surface Treatments – Application of zinc-nickel to give the part high corrosion resistance and durability, essential for its application in the automotive sector.
- Inspection – Rigorous quality control and dimensional conformity of the part, ensuring that each compression limiter meets technical specifications.
The integration of these processes under ETMA’s roof resulted in solid and predictable industrialisation, transforming a complex challenge into a successful solution with an annual production of approximately 300,000 parts.
COMPETITIVE ADVANTAGES OF CHOOSING ETMA
This case study clearly illustrates the strategic advantages of collaborating with ETMA:
- Flexibility and variety of processes: The ability to combine different manufacturing technologies allows for finding the most optimised solution for each challenge, even the most complex ones.
- Customised solutions and co-engineering: ETMA works closely with clients, from the initial design phases, to develop tailored solutions that meet their specific needs.
- Technical capability and innovation: The team’s experience and know-how, combined with modern machinery, drive innovation and the creation of new production approaches.
- Reduced interfaces and total control: By integrating multiple processes internally, ETMA minimises reliance on third parties, optimising lead times, costs, and ensuring rigorous quality control at all stages.
- Quality and reliability: The commitment to robust processes and continuous inspection ensures the delivery of high-quality components, essential for sectors such as automotive.
CONCLUSION: THE IDEAL PARTNER FOR YOUR METAL CHALLENGES
The development of the compression limiter for the automotive sector is a testament to ETMA’s ability to transform complex challenges into successful industrial solutions. The strategic combination of turning and stamping, supported by its 10 Integrated Production Processes, demonstrates not only its technical versatility but also its commitment to innovation and customer satisfaction.
If your company is looking for a partner with co-engineering capabilities, production flexibility, and rigorous quality control for its metallic components, ETMA is the right choice. With extensive experience in prototyping and large-series production for the most diverse sectors, we are ready to face your next challenge.
Contact us and discover how we can optimise your projects.