Case Studies - Applied Component Technology
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Case Studies

Our experience, flexibility and agility mean we are able to supply directly to the OEMs and also through tiered suppliers.

This works best when we are involved as early as possible in the project and where we can provide our technical expertise to make sure the manufacturing process is right first time. However we can also help solve existing problems for the customer, whether they are technical, quality or logistical.

Don’t just take our word for it, below you will read how a number of companies have experienced the ‘ACT’ difference.



The challenge: To design and develop a low volume loadnet for the accessory market. This was intended for a specific vehicle, with an annual production demand estimated at just 200 units.

The ACT approach: We amortised the development costs for the loadnet over the lifetime of the vehicle, minimising the up-front investment costs for the customer. By manufacturing the product on an existing flexible cell, this also minimised the investment needed in tooling.

Results: ACT will start supplying the loadnet later this year. It has been designed, developed and tested within a stringent 16 week lead-time.



The challenge: To reshore the manufacture of injection mouldings from Asia to the UK, ensuring the customer received deliveries within 48 hours from receipt of purchase orders.

The ACT approach: We identified and sourced a good quality sustainable grade of recycled polypropylene, which fulfilled the technical requirements of the product at an affordable price. Minimum and maximum finished good stock levels were also maintained to take into consideration the seasonal demand for the products.

Results: ACT successfully started manufacturing three variants of one product, with a second product – boasting a further three versions – now also in production. Boosted by the successful reshoring exercise, the customer is expected to place more orders for development products shortly.

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The challenge: To solve technical issues relating to the chrome plating of a challenging long moulding, with a shot weight of just 225g on a 900T injection moulding machine…all using existing tooling.

The ACT approach: We developed a manufacturing process to minimise the quality issues within the moulding, which could subsequently impact on the chrome plated finish. Working closely with our customer, whilst monitoring the quality levels on each batch, enabled the moulding process to be optimised.

Results: The finished chrome plated moulding is currently being used by a luxury vehicle manufacturer.

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The challenge: The aerospace sector is currently exploring new ways to make components lighter and one area identified was the weight of the traditional galley cart used to supply refreshments to passengers.

A lighter, durable and more secure option was in demand by airlines, but no one had yet come up with a cost effective solution.

The ACT approach: Using our design team and expertise in nove lcomposites, injection moulding and supply chain management, we were able to develop and manufacture the ‘SmartCart’, a lightweight galley cart that is 10kg lighter than most rivals. This was achieved through the commercialisation of FibriRockTM, a remarkably strong and lightweight bio composite. The introduction of a new electronic seal that offers improved security, traceability and eliminates expensive and time-consuming plastic seals.

Results: SmartCart has the potential to offer airlines up to £17m of fuel savings every year, not to mention significant cuts in emissions that will help improve the environment. In a security conscious world, the ability to control exactly who has access to galley carts is also generating interest around the world.

The team at ACT were recognised for this launch with the award of the EEF’s ‘Smart Product of the Year’ prize. A £1m investment on a new manufacturing line has been well spent, with orders for 4500 units already secured.