Problem:

 Die-cast metal air motor components require costly secondary finishing operations.
Solution:

At HDI, we worked extensively with our customer to design and develop a new air motor molded out of a high strength thermoplastic resin (Dupont Zytel Nylon 70G33 HS1L).

In testing of the air motor, results show it is capable of withstanding nearly 9 times the maximum stresses that occur during use. The switch from die-cast metal to molded resin has eliminated all of the costly secondary finishing operations (saving thousands of dollars) as well as extended production tool life (plastic injection molds will typically last 3 to 4 times longer than die-cast tooling).

 

Problem:

Develop a new solenoid valve body to control air operated windshield wiper systems.
Solution:

Injection mold a one-piece valve body using thermoplastic materials. HDI molds the solenoid operated valve using glass filled nylon resin (Dupont Zytel Nylon 70G33 HS1L). We also mold a silencer for the valve body out of high performance acetal resin (Dupont Delrin 100P).

Due to the durability of nylon resin, the valve body can withstand rough handling during intsallation and maintenance as well as provide secure retention of presssed-in metal fittings. In HDI's testing, fitting joints within the valve body have proven to provide an airtight seal at pressures of 120psi. The use of glass filled nylon provides the molding consistency needed to maintain very critical tolerances that directly effect valve performance. HDI adds value to this project by fully assembling, testing, and packaging the complete product.


Problem:

 Large steel spanner nut rusts and seizes on the front of Heavy Duty Vehicles.
Solution:

HDI helped to develop then produce the spanner nut using a glass filled nylon resin (Dupont Zytel 70G33 HS1L) which not only eliminated rust stains, but also allowed these parts to be painted to match the exterior color of the vehicle. Spanner nuts molded from glass filled nylon can be removed easily, even after prolonged service and won't damage brackets if cross-threaded. Molding the spanner nut also costs less than the carbon steel part saving about 75% in each piece.