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Metal-to-plastic conversion is a decades old concept, and it remains a popular option for addressing concerns about component or end product cost, weight, manufacturability and compliance. While metal-to-plastic conversion is effective, many industries — notably automotive, defense and medical — are leaning into it further in order to reap more benefits by consolidating multiple existing parts into a single complex injection molded plastic part.
More manufacturing companies—especially automotive—are becoming aware of converting existing metal products or parts to plastic. Plastic parts have the same tight tolerances and are just as tough as metal parts. Plastics can be engineered to have specific characteristics for particular applications that are better than metal. Plastic parts are typically up to 50 percent lighter in weight than metal parts and converting from metal to plastic can significantly reduce total manufacturing costs.
Converting metal parts to plastic is becoming an increasingly standard practice in a number of industries from automotive to defense and public safety. The decision to use plastic instead of metal seems like a no brainer given the many advantages like lighter weight, lower material costs, quicker manufacturing times and extended tooling life.
Federal Corporate Average Fuel Economy (CAFE) Standards coupled with heightened consumer sensitivities to the environmental impact of using fossil fuels are tightening fuel consumption requirements for the auto industry.
The U.S. Department of Defense (DoD) has long faced the dilemma of balancing the safety and welfare of military personnel with the need for reducing the weight of armed forces gear and equipment.
Metal-to-plastic conversion is a decades-old process, but not all manufacturers are taking full advantage of its benefits. There is general, common concern about strength, durability and cost; however, the reality is that injection-molded plastic components, when properly designed, are just as strong as metal. In addition, plastic can provide exceptional chemical- and heat-resistance while simultaneously slashing production costs.
Since 1975, the automotive industry has been under governmental mandate to improve the average fuel economy of cars and light trucks manufactured in the United States. The Corporate Average Fuel Economy (CAFE) standards, born out of the Arab Oil Embargo of the mid-70s, are still in effect today with recently added emphasis placed on further improving fuel economy, reducing greenhouse gases and saving people money at the gas pump.