The Challenge
The client presented Catalyst with an extremely complicated part for prototypes and pre-production/production samples. Due to the complexity and part size, it was considered an experimental tool, which is often used to validate the design integrity and efficiency of a part. In addition, every other part in the assembly depended on this one part. There was little time for part/tooling optimization for manufacturing. The original files indicated the part would need:

· 18 side actions
· 8 molded-in brass inserts
· Heat staked inserts
· Overmolded bearings

All of which have been shown to significantly decrease production efficiency. Catalyst often works with clients on experimental tools that challenge the "normal" process and push the limits of part design. Due to the complexity and part size, this part fell into that category. The Catalyst tooling managers worked hand in hand with the client's design team to ensure the design intent and integrity of the part was not jeopardized. With the number of side actions and brass inserts required by the part, the design and tool had to be on target.

The Catalyst Difference
Catalyst prides itself on the ability to push the limit of tooling design and injection molding, making what has never been possible a reality. This particular part started the process with four men running the injection molding press due to the number of side actions involved. Before production was complete, they had fine tuned the process so one man could run the press even with 18 side actions. That is the Catalyst difference: trying new ways, thinking on our feet, doing whatever it takes to make your project successful. The proprietary rapid tooling process allows Catalyst to decrease time to market compared to conventional tooling processes.

The Result
The original design of the part remained intact and Catalyst was able to provide the client with the pre-production parts they needed