Piston Assembly

Problems

Sienna was tasked with the challenge to make a complex plastic piston assembly part as per customer print, that included intricate injection insert molding and ultrasonically welded seals.
The seals had to be sandwiched to a weld strength of 1000 newtons and leak proof between the fuel and non-fuel side plastics.
The complexity of making this part stems from the fact that each component that makes the whole assembly has intrinsic profiles and tolerances that play differently in the final assembly even if the child parts are made to print.

Sienna was tasked with the challenge to make a complex plastic piston assembly part as per customer print, that included intricate injection insert molding and ultrasonically welded seals.
The seals had to be sandwiched to a weld strength of 1000 newtons and leak proof between the fuel and non-fuel side plastics.
The complexity of making this part stems from the fact that each component that makes the whole assembly has intrinsic profiles and tolerances that play differently in the final assembly even if the child parts are made to print.

Sienna successfully developed the part and designed the process for mass production that consistently met the print and testing criteria.
Given the interplay between the tolerances and the potential for something to go wrong, we further narrowed the tolerance band to ensure that there is form, fit and function.

Sienna successfully developed the part and designed the process for mass production that consistently met the print and testing criteria.
Given the interplay between the tolerances and the potential for something to go wrong, we further narrowed the tolerance band to ensure that there is form, fit and function.

First successfully developed sample delivered in 4 months. The lead time included Tool development time.
Successfully ramped up production and have so far delivered 40,000 pieces.
Sienna as a supplier reduced customer rejection rates from 10% to 0%.
Sienna has the opportunity of being selected as the primary source for this part for the customers global production sites, due to increased consistency in weld strength and leak rate.

First successfully developed sample delivered in 4 months. The lead time included Tool development time.
Successfully ramped up production and have so far delivered 40,000 pieces.
Sienna as a supplier reduced customer rejection rates from 10% to 0%.
Sienna has the opportunity of being selected as the primary source for this part for the customers global production sites, due to increased consistency in weld strength and leak rate.