Optimized Development and Production of Dump Buddy by FCE through Precision Injection Molding

Dump Buddy, specially designed for RVs, uses precision injection molding to securely fasten wastewater hose connections, preventing accidental spills. Whether for a single dump after a trip or as a long-term setup during extended stays, Dump Buddy provides a highly reliable solution, which has made it a popular choice among consumers.

This product consists of nine individual parts and requires a variety of production processes, including injection molding, overmolding, adhesive application, printing, riveting, assembly, and packaging. Initially, the client’s design was complex with numerous parts, and they turned to FCE to simplify and optimize it.

The development process was gradual. Starting with a single injection-molded part, FCE progressively took on full responsibility for the entire product’s design, assembly, and final packaging. This transition reflected the client’s increasing confidence in FCE’s precision injection molding expertise and overall capabilities.

Dump Buddy’s design includes a gear mechanism that required detailed adjustments. FCE worked closely with the client to assess the gear’s performance and rotational force, fine-tuning the injection mold to meet the specific force values required. With minor mold modifications, the second prototype met all functional criteria, providing smooth and dependable performance.

For the riveting process, FCE customized a riveting machine and experimented with different rivet lengths to ensure optimal connection strength and the desired rotational force, resulting in a solid and durable product assembly.

FCE also engineered a custom sealing and packaging machine to complete the production process. Each unit is packed in its final packaging box and sealed in a PE bag for added durability and waterproofing.

Over the past year, FCE has produced over 15,000 units of Dump Buddy through its precision injection molding and optimized assembly processes, with zero after-sales issues. FCE’s commitment to quality and continuous improvement has provided the client with a competitive edge in the market, underscoring the advantages of partnering with FCE for injection-molded solutions.