Research Project Information

Research Project Summary Information

Energy Efficient Manufacturing of Gas Direct Injection Seats (25223)

Saturn Industries, Inc.


Saturn Industries manufactures the counterbore holes on Gas Direct Injection seats for Delphi at a prototype scale (2,500 parts/day). Currently, Delphi sends the GDI seats to Switzerland for the counterbore and through-holes. Delphi has asked Saturn for a quote on full scale manufacturing (40,000 parts/day) on both the counterbore and through-holes to avoid flying the parts to Switzerland.

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Project Description

Saturn Industries is partnering with the RPI Center for Automated Technologies and Systems (CATS) to develop a full scale machine that will produce the counterbore and through holes while maintaining tolerances, at the rate of 40,000 parts/day in an energy efficient manner.


The energy benefits realized with the new machine would be associated with the increased throughput. By creating the new machine, Saturn will only be running one machine for two shifts instead of the two current machines running for three shifts. This is expected to reduce the energy consumption by 20% or by 176,904 kWh/yr of grid supplied electricity.

Project Results


Saturn Industries, Inc.
Po Box 367
Hudson, NY 12534

Principle Investigator

John Lee

Universities Involved

Rensselaer Polytechnic Institute


Project Type:

Product Demonstration

Technologies Types:

Industrial Products

NYSERDA Contact Information

Miriam Pye


R&D - Mfg Tech & On-Site Pwr

Contract Details

Start Date: 3/26/2012
Project Status: Active
Contract Number: 25223

Last Updated: 7/30/2014