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Metal Replacement Re-Design

A product re-design that delivers on many levels

Orluna LED Technologies designs and manufactures a range of high-quality, bespoke light fittings that enable designers and architects to deliver a premium lighting effect.

The Hertfordshire-based company had historically relied on expensive metal components, which restricted their design freedom, and forced them to source from overseas, incurring unwanted environmental as well as financial costs.

Orluna sought to create a range of replacement plastic injection moulded components to give them greater design flexibility and to allow them to source from the UK; adding value, reducing cost and shrinking their environmental footprint.

Replacing metal with plastic injection moulded components

Understanding the greater design freedoms afforded by plastic, but without wanting to start the design process again, Hymid worked closely with Orluna to create replacement plastic components that performed as well, if not better than, their metal alternatives.

The benefits included:

  • Good tensile strength: greater component design flexibility with more complex geometry possible

  • ​Greater corrosion resistance: no post-manufacture coating required

  • ​Wider variety of raw materials available: lower raw material costs

  • ​​Reduced part weight: lower production, packaging, and shipping costs

Choosing the right development partner

The switch from metal to plastic components presents many different design challenges, so working with the right development partner was vital.

Orluna relied on Hymid’s expertise in component design and development to provide a proof of concept to further develop.

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