Solutions
For nearly 25 years, Royal Technologies has given our customers a competitive advantage with high-quality, forward-thinking plastics solutions. Click on any one of the case studies below to see firsthand how we do it.
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Precision Optics
Precision lenses perform a wide variety of tasks related to automotive safety. One customer asked us to help make their lenses even more precise.
Royal Technologies developed a class 100000 clean room, as well as a variety of automated production and testing procedures. The resulting lenses were 35% less expensive while providing a 30% increase in functionality.
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Zody Chair Back Assembly
Good design is integral to the furniture industry—not only in appearance, but structurally as well. One client asked us to take their prototype design for a revolutionary new task chair and make it production-ready.
The final design weighed less than 30% of the original while maintaining all of its original functionality. In addition, we were able to lower the cost by roughly 30% and improve the piece’s overall aesthetics.
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Automotive Side Shield
Designing for the automotive industry means navigating a minefield of complex challenges and requirements. One manufacturer approached us with a problem: their prototype side seating shield was expensive to produce and very difficult to manufacture, and they needed an alternative option.
Our prototype, though slightly heavier, is less expensive to produce and far easier to assemble. In addition, because of the material and manufacturing processes we employed, our prototype allows much more flexibility for aesthetics.
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Cut TDI to Molded MDI Foam Conversion
Cut TDI foam has a number of setbacks. This particular piece, for example, required that three individual shapes be cut from two different thicknesses of material, glued together to form a rough cushion, and then shaped for comfort in assembly.
Royal Technologies developed a one-piece molded MDI foam cushion. Because the MDI cushion is molded to shape, upholstery is much easier and faster. Additionally, MDI foam doesn’t lose its form like TDI, so the finished product stays comfortable longer.
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Aeron Chair Arms
Herman Miller’s Aeron chair is a legend, as is the company’s commitment to environmental sustainability. From a green perspective, however, the chair’s armrests were a weak point. Herman Miller asked us to propose a cost competitive, locally produced environmentally friendly alternative to injection molded PVC.
Working with Intex, Royal Technologies developed an armrest from a self-skinning polyurethane foam, eliminating the use of PVC entirely while at the same time simplifying production and cutting both the cost and weight of the finished component by roughly 20%.
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File Compressor Conversion
For many applications, plastic offers several of the advantages of steel with none of the disadvantages. One company asked us to look at the viability of converting their file compressor, which helps to minimize the space files take up in a file drawer, from steel to plastic.
Royal Technologies designed a prototype, injection-molded ABS plastic file compressor. In addition to meeting every performance requirement, our proposed compressor weighs less than 30% of its steel counterpart at roughly 70% of the cost.
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Arm Assembly Redesigned
A well-known furniture manufacturer asked us to take a look at the arm for a new flagship chair model. Initial prototypes did not meet the necessary strength requirement, were too expensive to produce, and were too difficult to assemble.
Royal Technologies redesigned several of the components and re-quoted purchased parts at local suppliers. In addition to improving the product’s strength and ease of assembly, we reduced the total number of components and lowered total production costs by nearly 15%.