- PPL worked with the customer from design through production, providing plastic engineering excellence to ensure the customer's success in the program.

- The customer was pleased with the fine details and part features that could be designed into the injection molded part as compared to the original metal part design.

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- PPL assisted the customer, and eliminated several aluminum parts by integrating the design features into the main housing and battery storage parts.

- The customer realized significant savings with the plastic injection molded design concept compared to a metal component design.

- The customer's initial design specified a metal housing. PPL recommended a polyetherimide (Ultem) with 20% glass fiber, which met the customer's requirements for a rugged, strong, durable, metal like material. The material also had to be paintable to provide the customer with high consumer appearance finish.

- PPL was able to meet the customer's tight tolerance requirements of +/- .0005 in spite of wall thickness variation that ranged from .019" to .300".

- PPL also was able to overcome strict gate surface restriction by providing the customer with a Hot Sprue into a cold runner option. This kept the gate on the internal surfaces of the part, which are not seen by the end user of the product.