One possibility was to use induction weld- ing in lieu of epoxy bonding. In induction welding, the needles are inserted into the plastic hub, and an RF generator is used to heat the needles. The RF generator works on the same principle as a microwave oven. As the needles get hot, the plastic melts, and the needles are bonded. Switching to induction welding would require an investment in RF generators and the associated tooling. But induction welding promised to reduce the cost of direct materials, eliminating the need to
buy and use epoxy. Savings of direct labor costs were also predicted because the welding process is much more automated. Adding to these savings were the avoidance of daily clean-up costs and the reduction in rejects.