Background
The pellet separator was designed to isolate pellets from powder and dust after the automatic pellet loader.
Traditional manufacturing methods produced the separator from multiple machined and assembled parts, which increased weight, assembly time, and cost.
The available space near the pellet loader was very limited, restricting design freedom and requiring multiple fasteners and subassemblies.
The Challenge
To redesign the pellet separator into a lighter, more efficient component that fits within the existing machine’s limited space — while reducing both manufacturing cost and complexity.
The goal was to maintain full functionality while consolidating the multi-part assembly into a single, integrated component.
Our Solution
Using AMBIT™ XTRUDE polymer extrusion technology integrated into a CNC, Hybrid Manufacturing Technologies created the pellet separator as a single printed and machined component.
The new design fit perfectly in the restricted space and reduced both manufacturing complexity and cost.
Results
💰 68% cost reduction compared to the previous assembly method.
🧩 Complex multi-part assembly replaced by a single printed and machined component.
💵 Over $750 system savings realized from redesigning the complete assembly.
💡 Design tailored to fit limited space, improving efficiency and performance.
Ready to rethink your production efficiency?
Hybrid Manufacturing Technologies Global can help you redesign and optimize complex assemblies into streamlined, single-piece components using hybrid polymer extrusion technology.
