DFM Analysis, Injection Molding Help Spring Company Reduce Costs

An Illinois-based steel-spring manufacturer recently called on Proto Labs to help reduce component count and save time and money on a device the company uses to market its services to the aerospace, automotive, oil and gas, and medical industries.

Smalley has long equipped its sales force with a small demo device, a handheld “comparator” that shows the relative size and performance of a wave spring—which Smalley manufactures—compared with a coil spring.

The company turned to Proto Labs for help with solving a cost issue when Smalley considered redesigning the comparator to “use them as ‘giveaways’ to prospective customers,” explained Lane Persky, Smalley marketing manager. “We were looking to go from about 20 of the original comparators, which each cost about $100 to produce, to an initial run of 1,000 redesigned comparators at a target cost of about $15 each.”

Proto Labs’ design for manufacturability (DFM) analysis, and its injection molding service, helped Smalley designers create a new comparator, which would require just seven parts. The original comparators each consisted of 23 parts.

“We chose Proto Labs for the company’s reputation and ability to do both advanced 3D printing for prototyping and affordable, rapid injection molding” for low-volume production, said Persky.


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