Fast-Track Tooling and Production for Xylem's Smart Metering System

Xylem is a global leader in water technology, providing innovative and sustainable solutions to move, treat, analyze, and return water to the environment. Their engineering teams work across product development, manufacturing, and automation to design reliable solutions that make water management smarter and more efficient.

Challenge: Delivering Production-Ready Tooling on an Accelerated Timeline

When Xylem set out to combine several of its products into a new smart metering solution, speed was critical. The project required the development of multiple plastic housings and covers to protect and integrate the electronics and water meter. 

The timeline was aggressive; the tooling needed to be designed, built, and producing parts within four weeks. The parts were also integral to the final assembly. Without them, the product could not ship.  

“We needed to move fast,” said Xylem’s senior mechanical engineer, John. “It was between Uptive and an overseas supplier, but Uptive was faster, more cost-effective, and I could visit the parts in person. That made all the difference.” 

In addition to the time pressure, the team needed the tools to withstand high-volume production without transitioning to full production tooling.  

Solution: Collaborative Design and Advanced Tooling

Uptive, through its Phoenix Tooling & Molding division, partnered closely with Xylem’s engineering team from prototype through production.  

The project included four injection-molded components: 

• Two main housings that hold the smart metering device and water meter 

• A lid and latching cover that must snap securely in place, yet allow for repeated opening and closing 

Uptive’s tooling experts reviewed the part design and offered recommendations to simplify manufacturing, including eliminating a slide or undercut by modifying snap features. 

Phoenix Tooling used Hokotol aluminum molds with Nibore coating, allowing the team to meet both short-run and high-volume production goals, without needing a separate production tool.  

When early drop tests showed that the snap featured needed reinforcement, Uptive’s engineers quickly redesigned and re-machined the tooling to resolve the issue – keeping the project on schedule.  

“The snaps gave way during testing, but Uptive fixed it immediately,” John said. “They handled everything exactly the way it should be done.”  

Results: Reliable, Worry-Free Performance

Xylem’s new smart metering system launched on schedule, with no part failures, no returns, and no tooling issues. The Nibore-coated aluminum tooling allows Xylem to produce a high volume of parts per year without investing in steel production tooling, delivering major cost and time savings.  

“Because not only was it timely, but the tooling was well done- and I didn’t need to worry about it,” said John. “Uptive does everything the way it should be done.” 

By choosing a domestic partner with in-person collaboration and flexible tooling options, Xylem achieved a faster time to market while maintaining the quality and reliability their customers expect.  

Partnerships in Action

Throughout the project, Uptive’s engineering and tooling teams maintained direct communication with Xylem’s engineers – including multiple on-site visits by Uptive’s technical lead to review parts and progress.  

“Jonathan Wilke was a big component of our success. He’s very supportive, makes sure our needs are met, and even visited the shop twice with me. The turnaround is just incredible.” 

The partnership has since expanded, with Uptive currently supporting a new molded assembly project for Xylem with similar tight timelines and design collaboration.  

“If you go to Uptive, expect to get your parts quickly and done the way you expect them. The tooling, the quality, the speed – it’s all there.” 

Key Outcomes

• 4-week turnaround from design to production tooling

• Cost savings vs. Overseas suppliers while maintaining domestic collaboration

• Nibore-coated tooling enabled high-volume runs without production steel tooling

• Zero returns or failures reported since launch

• In-person engineering support and design optimization throughout the process