The original design of the ice cleat called for a closed-die forging.  But this was a new item purchase, and there were no forging dies on hand.  New dies would have to be designed and made, but would require almost six months of lead time for dies and a total lead time of 10 months for prototype production (80 cleats). 

There had to be a faster manufacturing technology which could meet production and performance targets. 

Two Faces of the Ice Cleat

A manufacturing study showed that a steel casting could be produced in a much shorter time, compared to a forging.

• Prototype tools could be made in two (2) weeks, , based on a CAD file and CNC machining of an aluminum tool.  The first production tool  for would be available at the 10 week mark.
• The foundry  can cast six cleats with one pour in a flask, using a multiple castings on a tree.  This raises the production rate.
• With a casting, the strength properties will be more uniform with no directional variations.

Bar Chart Showing Lead Time Comparison