V-Spacer – Refrigeration Industry Application

This project came from a customer manufacturing insulated panels within the refrigeration sector. At the time, they were using a simple wooden block as a spacer using production. It did the job, but it wasn’t consistent.

Depending on how the block landed inside the recess, positioning could vary slightly. Over time that kind of variation slows production and adds unnecessary handling.

They were looking for a purpose-designed spacer that would hold the correct dimensions every time, regardless of orientation. Injection moulding was agreed as the manufacturing method from the outset, as the part would need to be supplied repeatedly and in volume.

The Challenge

Replacing a wooden block might sound straightforward. Once we reviewed the process more closely, it was clear there was more involved.

The spacer needed to function correctly however it was placed within the recess. That meant the geometry couldn’t rely on “right way up” positioning. It had to work either side up without adjustment.

There was also a realistic development timeline to manage:

2-3 weeks design development

4-5 weeks for tooling manufacture

10-14 days for initial production

Beyond geometry and timescale, the aim was simple: reduce production time and remove unnecessary movement and consumable usage from the customer’s process.

Our Approach

We began reviewing material options. Based on the operating environment and strength requirements, Nylon 66 was selected. It offered durability and dimensional stability while remaining suitable for injection moulding.

The design was developed in CAD, but before committing to tooling we produced early proving samples in wood. This allowed the customer to trial the concept in real conditions without the cost commitment of steel tooling.

Once the form was confirmed, we proceeded with multi-cavity tooling. This decision helped keep unit cost competitive and supported long-term supply at higher volumes.

Small adjustments were made during development - as they usually are - but addressing them before tooling was finalised made the rest of the process straightforward.

At Allthread Plastics, taking a design from concept through to a finish injection moulded product is something we do regularly. This project followed that same path.

The Outcome

The finished V-Spacer replaced the wooden block with a more consistent and reliable component.

In practical terms, it delivered measurable improvements:

Reduced the customer’s production time by approximately 50%

Removed orientation-related positioning issues

Replaced a dated manual method with a moulded Nylon 66 component

Progressed to large annual supply volumes

The spacer is now part of the customer’s standard insulation panel manufacturing process. What began as an efficiency improvement became a long-term solution.

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V-Spacer – Refrigeration Industry Application

The Challenge

Our Approach

The Outcome

Materials and Production Details

Key Takeaway

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