A leading powersports manufacturer faced an unexpected challenge: four tools were cut to the wrong shrink rate, leaving every door panel undersized. The ripple effect? Windows stuck in cold weather, creating a serious performance issue. The fix had to deliver the same durability as the incumbent material and withstand harsh environmental conditions, without scrapping the existing tooling. Rebuilding could cost more than $1 million and months of downtime.
Turning Material Science Into a Solution
The customer corrected both the shrink and window-sticking issues without retooling. This approach saved six months of production time and prevented high scrap rates. Formerra’s ability to resolve the cold-weather sticking problem was pivotal in securing material approval, eliminating additional testing costs and delays.
Results That Save Time and Capital
The customer corrected both the shrink and window-sticking issues without retooling. This approach saved six months of production time and prevented high scrap rates. Formerra’s ability to resolve the cold-weather sticking problem was pivotal in securing material approval, eliminating additional testing costs and delays.
The Power of Collaboration in Problem-Solving
What seemed like an obvious answer—scrap the tooling and start over—wasn’t the smartest path. Formerra approached the challenge from a material science perspective, delivering a custom performance solution that optimized molding processes and met tight specifications.
Formerra’s value goes beyond problem-solving. Customers gain access to an extensive material portfolio, direct connections to industry experts, and coordinated conversations with leading suppliers, all designed to accelerate success and reduce risk. Explore our Powersports Success Guide to discover real-world examples of how Formerra helps OEMs overcome costly retooling, scrap reduction, and lightweighting while preserving performance.
