Electric vehicle manufacturers know that weight reduction is critical for range, safety, and efficiency. For one leading EV brand, the challenge was clear: reduce the weight and production cost of its midsize luxury SUV without sacrificing performance. The solution needed to be implemented quickly to achieve immediate savings and avoid any production line downtime.
Meeting Weight and Cost Goals Under Pressure
The client aimed to convert multiple metal components to plastic to lower weight and cost. The timeline was tight, and any delay could disrupt production schedules and impact profitability.
PC/ABS Expertise and Hands-On Support
Formerra partnered with the client to execute a strategic metal-to-plastic conversion using PC/ABS solutions, including color-matched and pre-colored grades. Delivering under pressure required deep technical collaboration and on-site support:
- Six mold flow analyses to validate design feasibility
- More than 30 engineering calls to align on technical details
- 29 full-day on-site visits at production facilities in China and the United States
Formerra also coordinated with a key material supplier to provide two days of on-site expertise, ensuring advanced technical knowledge was applied throughout the process.
Millions Saved and Zero Downtime
The impact was significant:
- Over $1 million in annual savings on vehicle production
- No disruption to the production schedule
- An additional $320,000 in annual savings through process and material consolidation
By streamlining PC/ABS solutions and guiding the client through every stage, Formerra delivered both immediate and long-term value.
Lightweighting Drives EV Performance
Weight is a consideration at every stage of electric vehicle development. It is a critical factor in vehicle range and safety. If there is an opportunity to convert metal components to plastic, designers will explore it. Formerra’s Technical Support team demonstrated exceptional commitment as the scope of this project expanded beyond the tier supplier level to include the OEM design team. The client valued the ability to leverage Formerra’s deep industry expertise as an additional on-site resource and used that knowledge to inform future designs and process development.
Explore our Mobility Success Guide to discover more real-world examples of how Formerra helps OEMs achieve lightweighting goals, reduce costs, and improve performance without compromising quality.
