Case Studies
Explore real-world case studies that showcase how we solve tough engineering challenges with high-performance polymers.
As the field of material science expands, so does our ability to create parts from these materials that will perform in the most demanding environments. From the more traditional industries like automotive and aerospace to the most innovative, newly emerging markets like space and e-mobility, our engineering team is problem solving for complex, precise parts.
The benefits of injection molding polymers, reduced production costs, weight and space savings, are well known. Here at Allegheny, our team adds another important element to our customer experience. Our expertise, and our collaborative, creative environment have enabled us to find solutions for even the most challenging applications. Our five step process enables us to work with our customers efficiently, and find innovative solutions in a time-efficient manner. You can read about some examples in our case studies below.
From Metal to Plastic: Defense Contractor Cuts Weight and Cost
“Even at low volume, [this component] generated significant cost savings, in addition to a reduction in weight without sacrificing performance or conductivity,” stated Andy Lesser, Allegheny VP of Sales.
Resolving a Critical Supply Disruption
Due to an unforeseen plant closure of the incumbent injection molder, the customer was left without a manufacturing solution and insufficient inventory. By streamlining the necessary protocols, our team was able to move the molds to our facility and return the customer to delivery deadlines.
Reshoring an Oncology Infusion Needle Assembly
A medical OEM needed to reshore six injection molds for their oncology needle infusion assembly. Our tool room team, engineers and production team were able to make repairs, and facilitate production - putting our customer back on track with demand.
Heavy-Duty Truck Ball End Retainer
Wrong material selection lead to this part failing in fatigue testing. APP was called in, identified correct material selection and recommended changes in design to produce a part in record time that passed all testing.
Outdoor PPS Heat Sink
Read about how Allegheny Performance Plastics helped a customer manufacture PPS plastic components to eliminate 100% component level testing through high levels of process control.
Friction Transmission Component
Learn how Allegheny Performance Plastics’ automotive plastic injection molding capabilities helped a transmission component supplier eliminate a potential failure mode.
Metal to Plastic Fan Conversion
A Fortune 100, Tier 1 aerospace manufacturer eliminated 45 days of lead time, reduced supply chain risk, and saved $20K annually by conducting value stream mapping on an entire product family of an aerospace fan part.
Large Thrust Washer
This Fortune 500 off-highway equipment manufacturer converted a metal thrust washer used in a transmission torque converter into a high-performance polymer, resulting in reduced weight, lower costs, and not a single failure in 10 years.
Needle Bearing Replacement
A multibillion-dollar powertrain component manufacturer for the automotive industry dramatically improved retention in its needle bearing product line and saved over $200K in annual costs.
Heavy-Duty EV Transmission Pinion Washer Replacement
New Torlon® washer eliminates the high failure rate of the original part, which was wearing out prematurely. There was an added benefit of a significant reduction in NVH.
