Modern engineering plastics — glass-filled nylons, polycarbonate alloys, high-temp polysulfones — match or exceed the strength-to-weight performance of cast aluminum, stamped steel, and machined zinc in a wide range of applications. We help you redesign, validate, and re-source the part.
— Weight reduction is on your spec sheet.
Drone, aerospace, mobile equipment, automotive aftermarket — every gram saved compounds across the system
— The metal version is over-engineered for its actual load case.
Many parts inherit "metal" from legacy design, not because metal is required
— You're paying for secondary work.
Machining, deburring, painting, anodizing, or coating that an as-molded plastic part skips entirely
— Corrosion or galvanic issues plague the metal version.
Plastic doesn't rust, doesn't pit, doesn't conduct, and doesn't react with what's around it
— Volumes are above ~5,000 units annually.
The tooling investment amortizes; piece price drops below the metal alternative
Most conversion projects move from first conversation to first production parts in this window. Faster is possible when the part is small or simple.
Bring us the original metal print, sample, or both. Our engineers review the part, discuss the load case, and tell you whether conversion is realistic. If it isn't, we'll say so on the call.
Once conversion looks viable, we run Moldflow on the candidate geometry and resin. Output: a documented recommendation with stress analysis, fill simulation, and trade-off discussion.
Soft tooling for 50–500 prototype parts. You validate function, fit, and field performance. We refine the design based on what you learn.
Hard tooling sized to your actual annual volume. First-article inspection, dimensional sign-off, and into the rotation.
03 What you can expect
33% glass-filled nylon 6/6
— the closest plastic equivalent to die-cast aluminum for many structural parts
Long-glass-fiber nylon
— for parts replacing stamped steel where impact resistance matters
Polycarbonate
— for cosmetic and impact-critical parts replacing thin metal stampings
PEEK and high-temp polymers
— when the application sees 200°C+ continuous service
Polysulfone
— for parts requiring repeated steam sterilization
Acetal (POM)
— for low-friction mechanical parts replacing machined zinc or brass
Send us the print and a sample. The 30-minute design review is free, and we’ll tell you in plain English whether conversion is worth your time.
