Aware of basic benefits gained from metal to plastic conversion, OEMs have been converting heavier metal parts into lightweight plastics for years. But what these same manufacturers may not know is that, as technology improves and new materials continue to improve, the number of parts suitable for conversion continues to grow as well.

Advantages to converting heavy metal parts to plastic are plentiful. Number one on the list? Lower production costs and, in certain cases, enhanced performance due to less design limitations and lighter weight raw materials (think automotive with better performance and gas mileage resulting from weight loss and superior engineering). Second to lower production costs, but closely related, is the opportunity to consolidate parts as a result of greater design flexibility. Part consolidation can mean real and substantial savings in manufacturing expenses.

Other benefits from metal to plastic conversion:

  • Highly repeatable process (less scrap)
  • Reduced need for value added secondary services like painting or machining
  • Material properties suited to particular applications
  • Extensive choices in color and surface appearances.

Plastic parts can also be put together using a variety of cost-effective techniques, including ultrasonic welding and over-molding.

But perhaps the biggest benefit from conversion to plastic parts is yet to be discovered. As progress towards smaller parts continues to spread across multiple industries—including medical components, electronics applications and automotive components—the corresponding uses for thinner, lighter weight plastic parts also increases.

So, if plastic parts have so many advantages, why aren’t more people converting to plastics? The short answer is that a lot of parts aren’t considered for metal to plastic conversion because people don’t realize all the available options. With more materials available than ever before, applications thought to require metal parts may very well be good candidates for converting into today’s stronger plastics.

Why choose metal to plastic conversion at KASO?

KASO engineers are well-seasoned experts at converting heavy metal parts to lightweight, low cost plastic parts without compromising structural integrity. Our engineering staff will work with you to evaluate your options for conversion and discover new solutions you may not have been aware of. At KASO, our knowledge of injection molded parts is based on extensive expertise in materials selection. In any application where plastics are being considered as a replacement for a metal component, the proper material selection is of vital importance. Through appropriate materials coupled with a sound sensible product design, KASO continues to lead the industry in successful plastics to metal conversions.

Let us help you:

  • Lower total costs
  • Reduce your product weight
  • Improve part design & performance

Contact KASO Plastics to learn more about metal to plastic conversion and our other plastic injection molding services.