Buckle with snap fit, designed to be as strong as steel and as light as paper.
Snap fit, entire assembly in one FIM mold.
Stronger, and six times lighter than steel.
Material: KyronMAX S™ series (carbon filled nylon)
Dimensions: 17x14.5x5 mm
With the possibility of high strength injection molding feedstocks, snap fits are easily obtained, as with this buckle. The material is a carbon filled nylon (KyronMAX S™ series) from Mitsubishi Chemical America, which is suitable as a metal replacement. Compared to steel, KyronMAX S™ is substantially lighter having a density of 1.31 g/cm^3 vs. 7,87 g/cm^3 of steel, and a tensile strength of 383 MPa, against steels 370 MPa.
The entire buckle assembly was made in one Freeform Injection Mold mold, and two full prototype design iterations were completed in one day.
An AddiFab employee describes the process that led to the final design:
“This design process began by making two different product designs in the morning. Then designing a unique mold for each, that would fit our injection molding machine. Within lunch time both molds where printed, cleaned, cured and ready for injection molding. By the next day, the products were trimmed and ready for test.”
The result was a buckle that can stand high impacts with out cracking while still be flexible enough to be operated with two fingers.