5 ways to save material in next generation products

Material prices are through the roof and many companies are struggling to stay competitive. Here are 5 ways you could weight and material optimize your product, save the planet resources and staying cost effective (at least if realizing it with z.trusion®)

1. Add ribbs / reinforcements to the structure

By adding reinforcement to a structure you can maintain it's physical performance while reducing material needed, in for example a vehicle bumper or roof beam.

2. Increase the surface variation 

By adding a 3D texture to a surface you can increase the distance heat has to transfer across the prouct from A to B, thereby improving insulation performance while reducing material needed.

3. Combine functionality

Integrate functions in one single part to reduce number of components and number of materials needed to realize the product. Like for example combining the fixation of cells with the battery pack structure.

4. Design for zero waste

Avoid after-processes creating material waste, like for example machining. Instead, consider manufacturing methods that are making use of only the material needed to make the product, like for example z.trusion®, injection molding or sheet metal forming.

5. Imprint a pattern onto your product

By adding a pattern or structure imprinted in your product you can reduce the material needed for the product while gaining an additional design element. Make sure to use processes generating no waste, like z.trusion®.

Material savings enabled by z.trusion®


Vehicle bumper beam


Vehicle roof beam


Window thermal break


Tab cooled EV battery pack

Find out how much material z.trusion® could save in your product line