Case Study: Harris Corporation achieves faster, lower-cost circuit-board testing with Protolabs' rapid insert molding

Rapid Insert Molding Leads to Lower Production Costs

Harris Corporation, a government and commercial contractor specializing in communications, space and electronic systems, faced a recurring, labor‑intensive problem securing circuit boards to a vibration test plate. Machined attachment points were costly and often misaligned for different boards, and Harris’ own plastic test fixtures required dozens of tiny brass inserts to be installed one‑by‑one via heat staking. To address this, Harris turned to Protolabs’ rapid insert molding service.

Protolabs insert‑molded the brass inserts directly into Harris’ customizable Cycoloy fixtures (20 inserts per 6x6 fixture), delivering parts in about 15 days instead of the 2–3 months typical of traditional molders. The change eliminated manual heat staking, saved two or more full days of labor on test runs, produced net cost savings despite slightly higher part/tooling costs, sped time‑to‑test, and earned recognition from Harris’ Business Excellence program.

Harris Corporation

Michael Murray

Principal Mechanical Engineer in Specialty Applications