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CASE STUDY - From Metal to Plastic Components


The Metal to Plastic conversion is taking parts that were initially made of metal and reproducing or re-engineering them out of plastic.

Metal to Plastic conversion has developed a lot of interest over recent years. Simply because plastic material allows for more freedom when it comes to design and cost-saving, with companies that convert from Metal to Plastic components (on average) see an overall saving of 25-50% in production costs.


• Design, Quality and Freedom: Plastic can be durable, more lightweight and have more aesthetic options than metal, and as a production material, plastic blends can be customised to meet specific environmental, structural, and operational demands. With the right design and choice of material, a plastic component will outperform metal.

• A Faster Process: Converting to a plastic conversion provides much faster manufacturing cycles. The accuracy of injection moulding also eliminates time-consuming multi-step processes like grinding and re-working final parts.

• Weight & Strength: Plastic parts are typically at least 50% lighter in comparison to metal parts offering smaller sizes and a decrease in thickness. Injection moulded plastics are also just as reliable as metal parts when it comes to withstanding pressure whilst eliminating the need for welding.

• Innovation: The freedom offered by plastic part manufacturing can promptly solve complex problems. Whether dealing with harsh environments, complicated shapes and processes structures or weight limits, a plastic part conversion can enable flexibility needed to find creative, innovative solutions.


Recognised for its cutting-edge design, Thompson Aero Seating engineer and manufacture full-flat bed airline seating. Thompson’s bespoke solutions maximises passengers’ personal space and through intelligent design, optimises every inch of the cabin.


The Crossen team got involved with Thompson Aero when they required assistance in redesigning and re-engineering their "easy-chain attachment". Due to its original method of production being too expensive and time- consuming to continue mass-producing in-house.

The Crossen team was then able to assist in the redevelopment and re-engineering of the component. Guaranteeing the safety and reliability of the passenger by building a construct that reduced original costings, saved time, and maintained the overall strength to that of the original metal component.


Wrightbus has been at the forefront of transport innovation since 1946, relentlessly pushing the boundaries with its commitment to quality, style, and safety. Market-leading with its low-floored bus, Wrightbus has been shaping the future of the industry, whilst moving in a greener direction with its zero-emission hydrogen double-decker.


Assisting Wrightbus in previous projects, their team came to Crossen to discuss a redevelopment in their vehicle's interior that reduced the overall weight of the public automobile but maintained the strength.

Working with the R&D team at Wrightbus, together we were able to come up with a solution to convert the support bracket components from metal-to-plastic components. Using our skills in design, prototyping and redevelopment the team were able to significantly reduce the weight of the vehicle offering greater fuel efficiency and improving the overall performance of the automobile in keeping with Wrightbus’s greener aspirations.