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Herman Miller Red Rocket
Solution: Herman Miller used CPI Binani’s DFT (Direct Feed Thermoplastic) process for formulating LFT (Long Fiber Thermoplastic) composite parts. The DFT process involves in-line compounding of resin and reinforcement, coupled directly with compression or transfer molding to form a finished part. Results: The manufacturer was able to develop a part made of fiber-reinforced Nylon 6, which withstood 300 pound cantilevered loads with minimal deflection. The nylon formulation was significantly stronger than a fiber-reinforced polypropylene design also considered, and still much less costly than the aluminum design previously used in such cases. Herman Miller saved $13.50 material cost per desk. Additional savings came from reduced weight, fewer tool builds, and elimination of part surface painting. Return to Furniture Applications Page
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Problem: In developing a new workstation product for students, “start ups,” and other customers, furniture manufacturer Herman Miller, Inc. wanted to substitute reinforced plastic for metal (aluminum) in a load-bearing furniture component. Reinforced plastic parts made by conventional composite manufacturing processes were too weak. A die cast aluminum part was too expensive.
