The Challenge

The cleat needed to cope with heavy weight in day-to-day use. That meant strength and resistance to wear were non-negotiable.

At the same time, the part had to fit a fixture that was already in production. There wasn’t freedom to increase size or alter mounting positions significantly.

Cost was the sticking point. Earlier design attempts were proving too expensive once tooling and cycle time were factored in. If the product couldn’t be made competitively, it wouldn’t move forward.

So the challenge was clear:

• Keep the mechanical performance
• Maintain compatibility with the existing fixture
• Bring the overall cost down

That balance is rarely straightforward.

Our Approach

Material choice was the first discussion. Given the load and wear expected, we recommended glass filled nylon. It offered improved stiffness and durability compared to standard grades and suited the application.

Cycle time then became a focus. Shorter moulding cycles were important if the product was going to be commercially viable in volume.

The bigger shift came in simplifying the original specification. Some features added cost without adding enough functional benefit. We reduced complexity by reducing roller bearings, easing back spring tension and wound length, and relaxing tolerances where they didn’t materially affect performance.

Those changes didn’t alter the purpose of the cleat. They just made it more practical to manufacture.

At Allthread Plastics, we’ve found that sometimes refinement is more important than reinvention.

The Outcome

The final cam cleat delivered what was needed. It held under load. It fitted the existing system. And it could be produced at a competitive cost.

In measurable terms:

• The product became price competitive
• Supply has continued for over 20 years
• The component is now used within finished systems distributed worldwide

The redesign didn’t just reduce cost. It produced a durable component with long-term mechanical stability.

Materials and Production Details

• Material: Glass filled nylon
• Manufacturing method: Injection moulding and assembly
• Design origin: Adapted from an existing product and simplified for cost and durability
• Key focus: Strength, wear resistance and commercial viability

Key Takeaway