DuPont™ Delrin® Acetal Homopolymer Outperforms Acetal Copolymer and Reduces Cost Per Part

Designing for Delrin®, a global customer gained significant cost savings

A major customer used Delrin® acetal homopolymer over acetal copolymer to redesign the next generation of their part. The result: thinner, lighter part design at same part performance that allowed the company to shorten production cycle time and to gain significant cost savings in part production cost.  

The Challenge

The customer was considering acetal copolymer for the next generation of their part, as the company was offered acetal copolymer at a discount to the price of Delrin®.

Original Design in Acetal Copolymer

Design in Delrin® 300TE

Design is disguised for customer confidentiality

The Solution 

DuPont offered support in part design to demonstrate the increased design flexibility with Delrin® at same part performance, and the potential for significant cost savings by delivering:

  • More strength and stiffness
  • More impact toughness
  • More creep and fatigue resistance
  • Higher flow rates

Delrin® outperforms acetal copolymer in mechanical properties. For the customer, these features translate into the potential for:

  • Increased design flexibility with thinner and lighter parts
  • Faster processing time

Both of which can lower cost per part through reduced material consumption and improved productivity of molding machines.

Optimized Part Design

In order to optimize the design of the part to fully exploit the superior mechanical properties of Delrin® while maintaining the necessary stiffness for part performance, DuPont engineers started with Delrin® 300TE, removed the ribs, reduced the diameter of the center thick section, and reduced wall thickness along the face of the part. 

The Advantages

By optimizing the part design for Delrin® the customer saw:

  • 21% weight reduction
  • 11% faster cycle time

This translated into 12% lower overall cost per part, relative to the copolymer alternative.

Key Takeaway

By focusing on design optimization using a resin with superior mechanical properties,  a lower cost per part was achieved.