Successes

Success Story #1: The Right Wrist Band for the Job

A customer contacted Astro Molding Inc. with a request that most companies would discount as impossible: to have a promotional wrist band designed and developed within 5 business days. Additionally, they needed a production run of 10,000 pieces in hand by the 7th day for presentation and sale to the consumer. (This wrist band was needed for a major media promotion.)

We had to engineer the band, including dimensions and logo lettering as part of the design, along with the appropriate tool design and fabrication, and manufacturing of a multiple-cavity mold. After tool construction was completed and approved, the job had to be set up to run to the customer’s specifications.

The Astro Molding Inc. staff embraced the challenge, and with continuous communication between the customer, the tool shop and manufacturing department, the job was completed successfully. Outstanding teamwork enabled the Astro staff to exceed expectations again--the parts were molded, inspected, delivered and approved by the customer on the 6th day, looking clean and ahead of schedule.

Subsequently, that satisfied customer has placed an additional 10,000 pc. order, with the expectation of up to a 500,000 pc. run at completion.

Astro Engineers Success.

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Success Story #2: Wiring Woes

The client invited Astro Molding Inc. to inspect the electronic assembly of their F-16 radio with hopes of correcting some assembly problems. The components included multiple wires and conduit that were installed, ty-rapped™ and epoxied in place by hand to prevent contact and electrical failure. However, the vibration of normal operation eventually caused failures to occur, despite these precautionary measures.

Astro was asked to recommend a failsafe solution to dampen the vibration, create electrical insulation and reduce manual assembly costs. Rubber and silicone are often the natural solution to such a problem.

Astro Molding Inc. designed a silicone insulation pad with raised supports in strategic locations to contain all the wires and conduit securely in place, eliminating vibration, wire or conduit contact and shorts, and ultimately, electrical failure.

The Astro Molding design was a two-fold success for the client:
1. It eliminated defects caused by electrical failure, thereby increasing production output.
2. It greatly reduced a tedious 3-step hand assembly to a single component installation, yielding a bottom-line cost savings of $160.00 per unit.

Astro Engineers Success.