Custom ABS Extrusion for OEM Component Replaces Metal Parts & Reduces Assembly Costs
How a custom ABS extrusion streamlined design, improved manufacturability, and reduced assembly complexity.
- Industry
- Transportation | Industrial Equipment | OEM Manufacturing
- Material
- ABS
- Process
- Custom Profile Extrusion
The Challenge: Replacing Multi-Part Metal Assemblies with a Lightweight, High-Strength Alternative
An OEM manufacturer was developing a new equipment platform and needed to replace a fabricated metal component with a lighter, more efficient solution.
The existing design relied on multiple parts, increasing manufacturing time, inventory requirements, and assembly costs. As production scaled, this complexity created bottlenecks and made it harder to maintain consistency across builds.
The team needed a single, custom plastic profile that could:
- Consolidate multiple fabricated components
- Hold tight dimensional tolerances
- Maintain a clean, consistent surface finish
- Withstand daily impact and use
- Support easy machining and assembly
- Scale reliably for high-volume production
Because the profile included multiple internal features and mounting surfaces, maintaining dimensional stability throughout extrusion was critical to ensuring proper fit and long-term performance.
The Solution: Custom ABS Extrusion Designed for Strength, Consistency, & Manufacturability
Lakeland Plastics worked closely with the customer’s engineering team to simplify the design and make it production-ready. The focus was on improving manufacturability while preserving structural integrity and appearance.
The team delivered:
- Design for manufacturability (DFM) review
- Custom tooling design and development
- Material evaluation and selection
- Prototype extrusion samples
- Fit and function validation
- Production process qualification
Engineering adjustments—particularly around wall thickness and material flow—helped reduce the risk of distortion during cooling, resulting in a more stable, repeatable profile in production.
The Manufacturing Process: Controlled ABS Extrusion for Repeatability & Consistent Product Quality
After the tooling was approved, Lakeland Plastics established a controlled extrusion process designed for consistency at scale.
Quality checks were integrated throughout production, including:
- Continuous dimensional inspection
- Straightness monitoring
- Color consistency checks
- Wall thickness verification
- Surface finish evaluation
- Final inspection before packaging and shipment
These controls ensured the profile maintained proper fit during assembly, prevented variation between production runs, and reduced the risk of warping or internal stress over time.
Production parameters were refined to maintain consistent geometry while supporting efficient, repeatable output.
The Results: Reduced Weight, Lower Costs, & Simplified Assembly with One Custom ABS Profile
The final ABS extrusion delivered clear operational and production benefits, including:
- Replaced multiple fabricated parts with one profile
- Lowered overall product weight
- Increased production consistency
- Provided a reliable domestic supply solution
- Reduced assembly time and labor costs
- Improved cosmetic appearance
- Simplified manufacturing and inventory
The new design streamlined production while maintaining the durability required for demanding industrial environments
Why This Project Matters: Using Custom Plastic Extrusions to Simplify OEM Manufacturing
Many OEMs are working to reduce product weight and eliminate unnecessary assembly steps without sacrificing performance.
For teams asking whether plastic can replace metal in structural or semi-structural components, this project shows how custom ABS extrusion can deliver both durability and production efficiency.
By consolidating multiple parts into a single profile, manufacturers can improve consistency, reduce total production costs, and create a more scalable design.
By working closely with customers from concept through production, Lakeland Plastics delivers extrusion solutions that support long-term manufacturing success.
FAQs: Custom ABS Extrusion for OEM Metal Replacement
Can ABS Extrusion Replace Metal Parts in OEM Equipment?
Yes, in many applications, ABS extrusion can replace fabricated metal components when the design requires a balance of strength, weight reduction, and manufacturability. In this project, a custom ABS profile replaced multiple metal parts while maintaining durability and improving assembly efficiency.
How Do You Reduce Assembly Costs in Multi-Part Metal Designs?
One of the most effective ways is to consolidate multiple components into a single extruded profile. In this case, Lakeland Plastics redesigned the part as one continuous ABS extrusion, which reduced assembly steps, lowered labor costs, and simplified inventory management.
Is ABS Strong Enough for Industrial Structural Applications?
Yes. When properly designed, ABS can deliver the strength, stiffness, and impact resistance needed for many OEM and industrial components. Material selection is application-specific and depends on performance and environmental requirements.
Talk to an extrusion engineer about your profile
Send a drawing, a sample, or a description of the part you need. We will review it for manufacturability and come back with a tooling and production path.