Quote requested for a stainless steel part that required a 300-hour salt spray test.
Proposed alternative ferrous material option to customer.
The difference was almost 50% less than the cost of the stainless steel part!!
Customer testing proved successful for alternative proposed version.
Estimated over $750,000 cost savings for the first year volume vs the stainless steel.
Over the last two years of production the savings has been in excess of $1,200,000 per year.
Finished Sintered Part Cost Less Than Stainless Material Cost
Finished Sintered Part Cost Less Than Stainless Material Cost
Customer had experience with plated copper-infiltrated connector lugs that required brazing tubes into the parts to move fluids within the engine compartment.
We worked with the customer to develop a flange that would meet the OEM specifications with a copper-infiltrated, plated part which would receive one or two stainless steel tubes brazed into the assembly.
The flanges would be mounted to an aluminum engine block and carry fluids to and from the radiator and the heater.
The total cost of the part delivered to the tier one supplier to the OEM prior to plating is less than the cost of the stainless steel powder alone – with no processing.
The flanges have been in production for three years with excellent quality performance and a significant savings to the OEM.
Material substitution for zinc diecasting
Saved $400,000 Per Year and Reduced Raw Material Variable Risk
Historically zinc diecast material cost relatively low lending diecast zinc parts as very economical.
Zinc soared from historical low levels of $0.50 - $0.70 per pound to over $2.50 per pound.
Customer searching for alternatives to Zn and requested quotes for non-ferrous alternate materials.
We quoted non-ferrous and ferrous options allowing for density to achieve drop-in replacement.
Average ferrous part < $1.50 each. Non-ferrous options $5.00 - $6.00 per part.
Cost of dies for castings typically 3 to 5 times the cost of powder metal tools.
Designed PM version as drop in replacement for customer eliminating need for product redesign.
Magnitude shift in commodity price variation to the customer with steel and iron vs zinc commodity.
material substitution for iron casting
Saved $650,000 Per Year and Increased Customer Product Performance
Customer historically utilized specialized grey iron components for a critical application in their product.
Costly grey iron version component due to need for full machining to achieve final features.
We were approached to come up with a cost effective PM alternative solution.
Able to go from fully machined grey iron version to near net shape PM version.
Higher overall strength with increased design margin.
30% customer cost savings with finished high precision PM component
Material substitution for cu-iron
Reduced Price by 20% with Expedited Customer Deadline
The customer was purchasing a Cu infiltrated component from a non-USA NAFTA facility and had tooled the part in a US facility. Supplier could not achieve PPAP.
Potential tool transfer to Dynametal to produce component.
20% of the cost of a new set of tools.
Full evaluation by focused engineering team led to ability of tool adaptation with tailored material alloy mix allowing precise sintered size change necessary to meet final dimensions.
We were able to expedite development and PPAP and deliver to customer at a reduced cost and freight savings.
20% cost savings - able to achieve final part without Cu infiltration.
Mitigated Customer Exposure to Copper Cost Fluctuations.