For those looking to reduce part costs without compromising performance, metal to plastic conversion can be useful. But while the cost savings are clear, many companies still hesitate.
Oftentimes, they’re uncertain about what the impact will be on the material strength, and whether the tooling investment is worthwhile.
In the sections ahead, we’ll walk you through what metal to plastic conversion actually involves, when it makes sense and share case studies of how other businesses have benefited from it.
What Is Metal to Plastic Conversion?
Metal to plastic conversion involves redesigning parts that were originally made from metal, and reproducing/re-engineering them using advanced engineering plastics. It’s often achieved through a molding process called injection molding.
Today, this method is used in automotive, industrial, and consumer goods sectors. As these are industries where high-volume production, part complexity, and cost-efficiency are an important consideration.
The Advantages to Metal to Plastic Conversion
It’s important to note that switching to plastic is not just about the material savings. In fact, it also gives companies the flexibility to create parts with intricate internal geometries, consolidate multiple metal components into a single molded piece, and lower shipping costs thanks to lower weight.
Apart from that. Unlike steel or die-casting aluminium. Engineered plastic also offers:
- Corrosion resistance
- Smoother surfaces
- Reduced requirements for assembly.
Taken together, these advantages make it very attractive to replace steel with composites. Especially in industries that demand speed and efficiency.
When Should You Consider Metal to Plastic Conversion?
Metal to plastic conversion is most effective when you're producing high volumes, facing rising metal or machining costs, or seeking design flexibility.
If your metal parts are driving up tooling maintenance, increasing assembly time, or limiting innovation due to rigid geometries. It could be a sign to look at engineered plastics.
This approach is valuable when:
- Your parts have repetitive, high-volume production cycles.
- You want to reduce weight in components for energy or shipping efficiency.
- You’re looking to combine multiple parts into one molded unit.
- Surface finish, corrosion resistance, or insulation are performance requirements.
- You want to future-proof your parts.
Metal to Plastic Conversion Example in Pump Housings (Case Study)
At Haizol, we recently helped a global motor pump manufacturer. They previously used die-cast to manufacture the pump's body shell. But its tooling life was limited to 50.000.
By switching to injection molded plastic, the company was able to produce over 1 million parts from a single mold, reducing downtime and cost per unit.
This metal to plastic conversion example shows how modern plastic components outperform metal in both scale and consistency.
Frequently Asked Questions
What Is Metal to Plastic Conversion?
It’s the process of redesigning a metal part for plastic manufacturing, typically via injection molding. The goal is to achieve faster, cheaper, and often lighter parts while meeting performance specifications.
What Are the Advantages to Metal to Plastic Conversion?
You gain reduced part costs, improved design flexibility, faster production, and longer-lasting tooling. All while reducing weight and waste.
Can Plastic Parts Really Replace Metal in High-Stress Environments?
Yes. With engineered plastics and additives like glass fibers, many applications no longer need metal to meet durability requirements.
Conclusion: Metal to Plastic Conversion: The Complete Guide
Metal to plastic conversion is typically achieved through injection molding. But the goal isn’t just to change materials. It’s also to improve design flexibility, reduce production costs, and scale manufacturing without compromising part quality.
At Haizol Global, we, as a metal and engineering plastic supplier and consultant, can guide you through every stage. From part redesign and DFM collaboration to tooling and high-volume production.
Whether you're replacing die-cast components or launching a new engineered plastic part, we are here to help you.