Case Study: Smalley slashes comparator cost and part count with Protolabs' DFM analysis and injection molding

R&D engineer uses Protolabs’ DFM analysis and injection molding service to reduce component count, save time and money

Smalley, an Illinois-based wave-spring manufacturer serving aerospace, automotive, medical and other industries, needed to redesign a handheld comparator used to demonstrate wave springs: the original device had 23 parts and cost about $100 each, so only a few were produced. Smalley engaged Protolabs for advanced 3D-print prototyping and rapid injection molding, using Protolabs’ ProtoQuote DFM analysis and molding services to pursue a high-volume, low-cost redesign.

Protolabs’ ProtoQuote flagged moldability issues and guided thinner-wall redesigns and material selection (Lustran ABS 433); Protolabs then produced the three molded components that eliminated a costly linear bearing and reduced the assembly to seven parts. The change cut part count from 23 to 7, enabled a 1,000-piece injection-mold run at a fraction of the original cost, and delivered fast turnaround and overnight design feedback—allowing Smalley to supply comparators as customer giveaways.

Smalley

Lane Persky

Marketing Manager