metal replacement
Metal replacement represents one of the most significant opportunities in modern manufacturing. At Cranfield Group, we specialise in transforming metal components into high-performance polymer solutions that deliver multiple advantages – from dramatic weight reduction to corrosion resistance and design freedom. Our expertise helps you achieve performance targets whilst reducing costs and improving manufacturability.
Our combined capabilities from Cranfield Solutions and Webb Injection Moulders bring together advanced material knowledge with precision manufacturing. We take ownership of your metal replacement challenges, managing everything from initial feasibility studies through to validation testing, ensuring your polymer components meet or exceed the performance of their metal predecessors.
Why Choose Cranfield Group
Proven Expertise in Engineering Polymer Solutions
- Advanced Material Knowledge – Expertise in glass-filled polymers, carbon fibre composites, and high-performance thermoplastics that match metal properties.
- Engineering Analysis – Finite element analysis and design optimisation ensuring polymer components handle required loads and stresses.
- Weight Reduction Expertise – Typically achieving 40-70% weight savings whilst maintaining strength and durability requirements.
- Cost Optimisation – Eliminating secondary operations like machining and finishing whilst enabling part consolidation and assembly reduction.
- Design Freedom – Complex geometries, integrated features, and multi-functional designs impossible or prohibitively expensive in metal.
- Validation Support – Comprehensive testing and validation programmes proving polymer performance equals or exceeds metal alternatives.
Our Metal Replacement Services
Our integrated services ensure successful transition from metal to high-performance polymers.
Metal replacement requires complete redesign for polymer processing. Our engineers optimise geometry, wall thickness, and reinforcement positioning for maximum performance.
Functional prototypes in production materials for thorough validation. We support your testing programmes with samples that prove polymer performance before tooling investment.
Precision moulding of engineering polymers including glass-filled grades up to 50% reinforcement. Consistent fibre orientation and dimensional control ensuring reliable mechanical properties.
Elastomeric alternatives to metal springs and vibration dampers. Custom compounds providing specific durometer and damping characteristics.
Insert moulding for hybrid metal-polymer assemblies, ultrasonic welding eliminating mechanical fasteners, and assembly of multi-component systems.
Complete assembly services transforming components into finished products. From simple sub-assemblies to complex multi-component builds ready for your production line.
Robust tooling designed for abrasive filled materials. Wear-resistant steel grades and specialised gating for optimal fibre orientation in structural components.
Protective packaging for high-value engineering components. Just-in-time delivery supporting your transition from metal supplier to polymer solution.
Ready to explore metal replacement opportunities? Our technical team can assess feasibility, recommend materials, and develop solutions that exceed your performance requirements.
Common Metal Replacement Applications
Metal replacement opportunities exist wherever weight, corrosion, or cost present challenges. We regularly convert aluminium housings into glass-filled polymer enclosures that maintain strength whilst adding design features impossible in metal. Steel brackets and mounting systems become lightweight polymer assemblies incorporating snap-fits, living hinges, and integrated fastening systems that eliminate hardware.
Our expertise extends to demanding applications like gears and bearings where self-lubricating polymers outlast metal alternatives, and chemical processing components where corrosion resistance provides decades of reliable service. From automotive under-bonnet components resisting heat and chemicals to marine hardware surviving salt water exposure, we deliver polymer solutions that solve real engineering challenges whilst reducing total system costs.
Meeting Metal Replacement Standards
Quality for Critical Infrastructure
Successful metal replacement requires rigorous validation. Our approach ensures confidence in polymer performance:
Material Selection
- Glass fibre reinforcement (15-50%)
- Carbon fibre for ultimate strength
- Mineral-filled compounds
- Self-lubricating polymers
Quality & Performance
- ISO 9001:2015 certified processes
- Tensile and impact testing
- Creep resistance verification
- Fatigue life testing
- Environmental stress cracking
Application Testing
- Load testing to failure
- Temperature cycling
- Chemical resistance validation
- Accelerated life testing
Leading engineers across industries trust Cranfield Group for metal replacement expertise. Visit us to see successful examples and discuss how polymer solutions can enhance your products.