Lowering Costs by Switching to UHMW-PE

Background Information

A manufacturer in Tokyo was operating a used overseas machine when it malfunctioned. During disassembly, a PTFE roller was found to be damaged. When the customer contacted the original manufacturer, they learned the part had been discontinued, making replacement components unavailable. The customer turned to Yumoto Electric for help producing a replacement part while keeping costs to a minimum.

Problem Statement

The challenge was to create a replacement roller that maintained the required sliding properties without over-engineering or incurring the high costs associated with PTFE (Teflon). The roller did not require the same level of heat resistance as PTFE, but it still needed to perform reliably under normal operating conditions. The customer needed a practical, affordable alternative that could be produced quickly.

Solution Implementation

After reviewing the machine’s operating conditions, Yumoto Electric recommended using UHMW-PE, a high-performance plastic known for its excellent sliding properties and durability.

UHMW-PE provided the necessary functionality for the roller while being significantly more cost-effective than PTFE. The material change eliminated the need for over-engineering and allowed the replacement part to be manufactured efficiently, meeting both performance and budget requirements.

Results

The UHMW-PE roller performed as required, offering smooth sliding and reliable durability. By choosing this alternative plastic, the customer avoided the high cost and long lead time associated with PTFE parts.

Customer Feedback

“Since the part was discontinued, we had requested quotes from several companies, but because they were quoting for PTFE, the prices were high. Yumoto Electric suggested UHMW-PE as an alternative that would meet our needs, and we went ahead with it. We had assumed the original material was essential, so it was a huge relief to reduce costs using a different material.”
— Manufacturing company, Tokyo