Creation of a complex plastic piston assembly part as per customer print. What made this part complex was the fact that each component had intrinsic profiles and tolerances which played differently in the final assembly, even if child parts were made to print.
Requirement of intricate injection insert molding and ultrasonically welded seals
Seals to be sandwiched to a weld strength of 1000 newtons and leak proof between the fuel and non-fuel side plastics
Given the interplay between the tolerances and the potential for something to go wrong, Avalon narrowed the tolerance band to ensure form, fit and function. As a result, we were able to successfully develop the part and design the process for mass production which consistently met the print and testing criteria.
Avalon was selected as the primary source for this part for the customer's global production sites, due to increased consistency in weld strength and leak rate.
- Sample Engineered and delivered in a single iteration (First time right).
- Successfully ramped up production and delivered 40,000 pieces
- Reduced customer rejection rates from 10% to 0%