How did we reduce tool costs by up to 7 times and speed up the implementation of a new component?
Is the technology chosen at the project stage always the right one? This question regularly arises among construction teams, R&D departments, and those responsible for investment budgets, especially when a project is nearing completion and the next step is investing in production tools.
W Geo Globe Poland We repeatedly encounter projects that were designed for a specific technology but can, in practice, be implemented much more efficiently. However, it happens that their geometry allows for a solution that significantly reduces implementation costs and increases production flexibility.
Below, we show an example where a change in approach allowed for a tool cost reduction of up to 7 times and a significant decrease in implementation time.
Who was the customer?
The client approached us with a finished model of a housing component of relatively large dimensions. The project was originally developed for injection molding technology and was prepared according to the typical principles for injection molding. This meant, among other things, uniform wall thickness, appropriate draft angles, and the absence of undercuts. At first glance, everything indicated that the technological direction had already been determined. The documentation was prepared, the geometry was organized, and the detail fit the logic of injection molding design.
What problem did the customer face?
The biggest challenge was not the component's functionality itself, but the economics of its implementation. In the case of injection molding technology, the client had to contend with the high cost of tooling, which represented a significant investment barrier at the project launch stage. The estimated cost of an injection mold ranged from 120,000 to 180,000 PLN. For a project that was to be launched in specific volumes and in a relatively short period, this meant a high barrier to entry, longer tooling preparation time, and less flexibility in the event of design changes.
The client needed an answer to a very specific question:
Is there a technology that will allow us to maintain the required functionality and aesthetics of a detail, while at the same time reducing implementation costs and shortening time to market?
Solution designed by Geo Globe Poland
During the analysis phase, our designers noticed that the component's geometry was beneficial not only for injection molding but also for vacuum forming. Crucially, the part had a „shell” form, did not contain complex internal details or undercuts, and its design allowed for relatively simple adaptation to another technology. We proposed an alternative production approach to the client, based on vacuum forming. This did not require a complete redesign of the component, but only a few deliberate design modifications. These included, among others, local increases in radii and optimization of thickness for material stretching during the forming process.
End result – what did the client gain?
The biggest change concerned the costs of entering production.
Instead of investing 120,000–180,000 PLN in an injection mold, the client completed the project with expenditures of only 20,000–30,000 PLN.
In practice, this has translated into up to a 7-fold reduction in investment costs!
However, this was not the only effect of the technology change. The implementation time proved to be equally significant. The fabrication of the thermoforming tool and the preparation of the CNC fixtures could be completed in just a few weeks, whereas with injection molding, this process would take several months. Additionally, the client gained greater flexibility during the product development phase. The lower tooling cost allowed for quicker responses to changes and more efficient implementation of design adjustments without the risk of incurring very high expenses. The change in technology from injection molding to thermoforming vacuum translated into several very specific business and project benefits. The client gained:
- Significantly lower entry barrier, without needing to invest a large budget in an injection mold.
- Faster implementation time, which allowed the project to be prepared for launch more quickly.
- Greater design flexibility, especially important at the product development stage.
- Better matching of technology to planned volumes, at a level of about 5,000–30,000 units.
- Sufficient functional and aesthetic quality, without compromise to the component's final application.
This project clearly demonstrated that the technology identified at the concept stage isn't always the best technology at the implementation stage. Sometimes, only a technological analysis allows for finding a solution that is cheaper, faster, and better suited to the client's needs. If the component's geometry allows for it, and the technology team is involved early enough, it's possible to find a solution that:
- will reduce investment costs,
- shorten the implementation time,
- increase the flexibility of the project,
- will not reduce the functionality of the final product.
That's precisely why, at Geo Globe Polska, we view projects not only through the lens of production itself but through the entire implementation process. From geometry analysis and technology selection to tooling preparation and production launch.
Have a project and wondering if the chosen technology is truly the best?
Consult with the Geo Globe Poland team. Sometimes, even a small change can significantly reduce implementation costs and speed up product time to market.