Product: Liquid Dispensing Cylinder Unit
Client Objective: Due to market pricing pressure cost reductions were required in both part and manufacturing processes as well as improved product performance and reliability in both leak strength and piston movement inside cylinder.
Solution: We eliminated the current hydraulic style assembly of the cylinder and replaced a number of components with a single end-cap designed with a shear type energy director. The tube end detail was also re-designed to match the shear energy director of the end-cap. The end-cap is then ultrasonically welded to the tube creating a solid leak proof welded joint.
Result: Eliminated 14 parts from original design, simplified the manufacturing process of all components and final assembly. Reduced cost of final assembly by $4.00, Incorporated a simple pressure leak test after assembly process to easily check for leakage.
Outcome: Product commercialized