VAVE for plastics

The easiest VAVE in history.

Mold insulation for the hot runner. Same press, same tool, lower part cost.

No tooling changes requiredYour existing molds stay exactly as they are.

Works on all current production partsApply it to parts already in production, no redesign.

15-20% faster injection molding cycle time
Better part quality
No PPAP (customer re-approval)
No budget, no risk

Implemented with Apple, Samsung, Ford and more.

Military-grade insulation

Book a discovery call →

Results

Lower part cost first. Energy and CO₂ come with it.

Four numbers that define the technology.

15-20%

Cycle time reduction

More parts per hour from the same press, same tool.

15-20%

CO₂ reduction

Lower hot runner temperature, less energy, fewer emissions per part.

3-12%

Savings on sell price

Agreed with your supplier up front. Shared savings model.

No budget. No risk.

No upfront cost, no retooling capital, no PPAP (customer re-approval). CSC is paid only from verified savings.

Better qualityEven hot runner temperature, more consistent parts.

Implemented with

MAGNA
LEAR
and more

Technology

How insulating the hot runner cuts the cycle.

1You buy plastic parts
2Your supplier molds them
3We insulate the hot runner
4Cycle time, cost and energy drop

Cooling drives 50-70% of injection molding cycle time. Most of it is waste.

FLIR thermal map of a molded door panel showing uneven hot (red and orange) and cold (blue and green) zones across the surface — Thermal mapping shows the hot and cold zones (blue and green are cold).

Without insulation, the hot runner runs hot and cold.

The hot runner manifold leaks heat into the tool, creating cold zones. To keep every zone above melt temperature, the whole hot runner is set about 70°F hotter.

✗ Hot runner at 450°F instead of 380°F
✗ Extra heat in every part: cooling 20s becomes 30s+
✗ Higher energy draw on every shot
✗ Thermal cycling shortens tool life

30 years of attempted fixes failed.

Asbestos: banned. Ceramic boards: too rigid, not durable. Then nothing for 30 years.

THE BREAKTHROUGH

Military-grade missile insulation, adapted for hot runners.

Survives 2000°F. Lasts the life of the tool. Installs during a normal changeover.

How it works

Insulate the hot runner. Lower its temperature. Faster cycles.

An evenly heated hot runner can run cooler, so there is less heat to cool out of every part.

STEP 1

Insulate the hot runner manifold

Removes the cold zones. Installed during a normal changeover.

STEP 2

Lower hot runner temperature 450°F → 380°F

Ejection temperature stays at 200°F. Less heat to remove.

RESULT

Cooling time 30s → 20s. Cycle 53s → 43s.

Lower part cost. ~20% faster cycle. Better quality. ~20% less energy and CO₂. No PPAP (customer re-approval).

Insulation that evens out the hot runner.

Wraps the hot runner manifold, not the whole tool
Stops heat leaking into the tool, so every zone runs at the same temperature
Hot runner drops from 450°F to 380°F: less heat to cool out of each part
Survives 2000°F, lasts the life of the tool
No PPAP (customer re-approval), no tooling changes

Cutaway of a hot runner manifold wrapped in insulation above the part cavity

Business case

Sized before anyone touches a press.

An OEM-wide business case, built before anyone touches a press.

We model the savings across your whole vehicle portfolio first. Then we filter down to the models and parts that carry the value, so the pilot starts where the money is.

We take 15% out of the plastic part.

Business cases we have built for automotive OEMs

Annual savings potential at a 15% faster cycle, across each OEM’s medium-to-large plastic parts.

Ford

North America

~$70M / year

$45M to $84M at 10% to 18% faster cycles.

~12,700 MWh energy saved a year~4,900 t CO₂ avoided a year

21 vehicle models
~2.7M vehicles a year (2027)
53 plastic part types

Volkswagen

Europe and North America

~$51M / year

€44M. Europe $39.6M, North America $11.9M.

6 platforms, 18 models
~2.8M vehicles a year
943 tools / molds

Toyota

North America

~$56M / year

$37M to $67M at 10% to 18% faster cycles.

~11,100 MWh energy saved a year~3,400 t CO₂ avoided a year

11 vehicle programs (USA, Canada, Mexico)
~3.1M vehicles a year (2027)
60 plastic part types

GM

North America

In progress

Business case being built.

Tesla

North America

In progress

Business case being built.

Stellantis

Europe and North America

In progress

Business case being built.

EXAMPLE: GLOBAL AUTOMOTIVE OEM (VEHICLE MAKER), EUROPE AND NORTH AMERICA

If this technology were applied across this OEM’s medium-to-large plastic parts, the results would be:

~$51M (€44M) a year in savings potential.

Consolidated annual run-rate across both regions’ production networks, at volumes from 2027 onward.

Platforms

Vehicle models

~2.8M

Vehicles / year

943

Tools / molds

EUROPE

€34M ($39M)

4 platforms, 12 models, ~2.2M units, 672 tools

NORTH AMERICA

$12M (€10M)

2 platforms, 6 models, ~600k units, 271 tools

Two filters: models first, then parts.

We rank vehicle models by savings, keep the ones that carry the bulk of the value, then rank the parts inside those models the same way.

EUROPE · 80/20 RULE

BASELINE

All vehicle models

12 vehicle models
~2.2M vehicles / yr
~55 parts per vehicle
672 tools

€34.3M

100% of total savings potential

STEP 1 · MODEL FILTER

Top 8 models

8 vehicle models
~1.6M vehicles / yr
~55 parts per vehicle
340 tools

€27.4M

80% of total savings potential

STEP 2 · PART FILTER

Top 31 parts in those 8 models

8 vehicle models
~1.6M vehicles / yr
~31 parts per vehicle
223 tools

€25.8M

75% of total savings potential

NORTH AMERICA · 65/35 RULE

BASELINE

All vehicle models

6 vehicle models
~600k vehicles / yr
~55 parts per vehicle
271 tools

$11.9M

100% of total savings potential

STEP 1 · MODEL FILTER

Top 3 models

3 vehicle models
~303k vehicles / yr
~55 parts per vehicle
136 tools

$7.1M

60% of total savings potential

STEP 2 · PART FILTER

Top 18 parts in those 3 models

3 vehicle models
~303k vehicles / yr
~18 parts per vehicle
42 tools

$3.1M

26% of total savings potential

Figures are annual savings potential at a 15% cycle-time gain. OEM anonymised.

Takes 20 seconds. Pick a part, enter your volume.

No upfront cost. No risk. We share the savings, then you keep them.

THE TERMS

No upfront cost for the customer or the supplier.
No-risk implementation for either side.
CSC is paid only when the workshop and negotiations succeed.
CSC shares 50% of the savings for 12 months.
After that, 100% of the savings go to the customer.

WHAT CSC DOES

Introduces the technology and runs workshops with your suppliers or your own molding plants.
Builds the business cases that pick the right parts.
Pre-negotiates before the workshop, typically 3-12% off sell price.
Completes the negotiations after the workshop.
Supports the supplier if a PPAP (customer re-approval) is needed.

WHAT THE SUPPLIER DOES

Comes with an open mind.
Embraces continuous improvement.
Allows cycle time and CO₂ to be reduced by ~15%.

Industries and parts

Any industry. Medium to large plastic parts.

Implementing at scale in automotive. Works for any industry and any plastic part.

Automotive
Packaging
Medical consumables
Consumer products
Appliances
Power tools

Parts that can benefit

Exterior

Front bumper cover
Front bumper shell
Radiator grille
Headlamp housing
Tail lamp housing

Interior

Door trim panel
Dashboard upper shell
Center console
Seat back panel
Instrument cluster housing

Under-hood

Engine cover
Air box
Intake manifold
Composite oil pan

And many more medium to large plastic parts.

If you mold any of these, almost certainly yes.

Materials we’ve proven

· PC (polycarbonate)
· ABS
· PA (nylon)
· PP (polypropylene)
· HDPE
· TPO, TPE, TPU
· Glass-filled grades

Excluded: thermosets.

Press range

· Minimum: 300 tons
· Preferred: 500+ tons
· Max: 4,500+ tons (no upper limit)
· Higher volumes = better economics
· Multiple cavities are fine

Bigger machines, larger parts and more volume all amplify the savings.

Applications

· Medium to large plastic parts
· Interior trim (dash, door, console)
· Exterior (bumpers, grilles, side panels)
· Under-hood (intake, air boxes, fan shrouds)
· Lighting, battery, seating, door modules
· Consumer, packaging, medical, power tools

~55 molded parts per vehicle are candidates.

When we screen a vehicle program, these are the injection-molded parts we look at first: exterior, interior and under-hood. Not every part makes the cut; the business case decides which ones do.

Exploded view of a sedan showing molded plastic parts: instrument panel, dashboard, door panel, bumpers, lamps, mirror, pillar trims, wheel arch trims, cooling fan, radiator frame and coolant reservoir — Molded parts on a typical sedan that mold insulation can speed up.

Exterior

· Front bumper cover
· Rear bumper cover
· Headlamp housings / lenses
· Tail lamp housings / lenses
· Exterior mirror housings
· Windshield cowl panel
· Wheel arch cladding & trim
· Main radiator grille
· Roof rail mount covers
· Front bumper lower skid plate
· Rear bumper diffuser / skid plate
· Water deflector cowl

Interior

· Dashboard AC vents
· HVAC air ducts
· Door card substrates
· Door map pockets / bins
· A-, B-, C- & D-pillar trims
· Scuff plates / sill guards
· Instrument panel carrier
· Dashboard upper structure & lower trim
· Instrument cluster & infotainment bezels
· Center console body, side trims & armrest base
· Console storage bins & front storage
· Wireless charger tray
· Overhead console housing
· Seat side valance & seat back shell
· Interior tailgate panel
· Cargo / 3rd-row side trims & trunk scuff trim
· Lower sill loading panel
· Glove box door & bin
· Steering column cowl

Under-hood & powertrain

· Engine splash shield
· Engine beauty top cover
· Fuse box housing
· Composite engine oil pan
· Air filter upper & lower box
· Battery tray & box
· Radiator fan shroud & impeller
· Trunk load floor structure
· Inner wheel arch liners
· Luggage compartment side pockets

Get started

Two gates, then go.

From NDA to workshop: two gates, then go.

Every part has to clear two milestones before anyone schedules press time: a positive business case and technical feasibility.

NDAs & part selection

NDAs signed. We identify candidate parts and molds.

Share cost breakdowns

Supplier cost breakdowns (CBDs) feed the business case.

GATE

Is the business case positive?

If not, we pick a different set of parts and run it again.

Introduce the technology

We introduce mold insulation to the supplier and review the mold CAD.

GATE

Is it technically feasible?

If the insulation can’t be installed on that tool, the part drops out.

Pre-negotiations

Savings agreed up front against 12% / 15% / 18% scenarios.

Kick-off & workshop

Scheduling, pre-workshop prep, then the on-press workshop.

Report-out

Results documented and negotiations closed.

From desk study to scale: the 4-phase rollout.

Pilot

Pick 2-3 parts. Prove the technology and capture the financial + capacity benefit. Internal: plant + ops + tooling eng. Supply base: buyers + tooling eng.

Plan at scale

Each plant manager identifies high-impact parts. Business cases developed, technical feasibility confirmed, 2026 savings budgets estimated.

Implement at scale

Global lead PM identified. Timelines, savings tracking, budgets in place. Projects launched and tracked across plants.

Future-proof

Tooling specs updated to include mold insulation and 10mm tolerancing. Future product costed at the lower structure, wins new business.

BIG-PICTURE POTENTIAL: INDICATIVE SAVINGS ON $10M / $20M / $30M OF APPLICABLE SPEND

Applicable spend	Low (5%)	Mid (8%)	High (12%)
$10M	$500,000	$800,000	$1,200,000
$20M	$1,000,000	$1,600,000	$2,400,000
$30M	$1,500,000	$2,400,000	$3,600,000

Real-world average is ~8% to sell price across the network. CSC is paid only from the verified savings. No upfront fee.

Case studies

Proof in production.

Recent: Stellantis door module. Jeep Grand Cherokee at scale.

RECENT PILOT

Stellantis door module

Automotive door module at a Tier 2 supplier in the Chicago area. Tier 1 sponsored the work; CSC ran the workshop on a 610-ton hydraulic Toshiba press with the panel-design tool.

CYCLE TIME

32.4s → 27.4s

−16%

HOT RUNNER TEMP

465°F → 380°F

−18.3%

Temperature stepped down progressively across both workshop days: 465 → 440 → 420 → 410 → 400 → 390 → 380 final. Cool time alone fell from 19.4s to 13.3s.

PRODUCTION SCALE

Jeep Grand Cherokee: 4-year impact

1100-ton hydraulic press, natural-gas powered facility, 620,540 units/year. After mold insulation: faster cycles, more parts per hour, dramatic CO₂ reduction over the model's run.

CYCLE

44s → 39s

PARTS / HR

164 → 187

ANNUAL KW

−12.5%

CO₂ SAVED OVER 4 YEARS

323,521 lbs

From a single mold on a single press

WHAT CLIENTS SAY

“We got 18% cycle time reduction without changing a single mold or machine.”

Plant Manager, Tier 1 Automotive Supplier

WHAT CLIENTS SAY

“It helped me generate additional savings of ~10% with my suppliers.”

Purchasing Manager, Global OEM

Track record

In production with leading manufacturers.

100+

Installations

Failures reported

100M+

Parts produced

300-4K

Tonnage range

CUSTOMERS RUNNING MOLD INSULATION IN PRODUCTION

BMWGMFORDSTELLANTISJEEPSUBARUMAZDAVOLVO TRUCKMAGNABROSEMARELLIBORGWARNERMANN+HUMMELNOVARISPLASTIC OMNIUMIACADIENTHARMANLEAROTTERBOXAPPLE SAMSUNG

Pay as you save: VAVE for plastics

Send your top 5 molded parts. We’ll quote the savings in 14 days.

Book a discovery call →