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Case Study: Metal-to-Plastic Substitution

The Challenge

Our customer, a leading supplier of automotive style products, came to us with a problem they were experiencing. They were looking to replace their metal boxes with a plastic version. Here at Thormac, we will always
moulding

The Solution

We spent over 1 man year and 1/4 of a machine year in finding the right plastic by running different samples in our 1100 tonne machine. 

We decided on the best design to make sure that the cooling was correct and began developing tools to the customers drawings and by making changes to the drawings. To solve the problem, we reduced the weight vital in the industry we were 

working with. As well as this, we increased the functionality of the box 

allowing further integration of the product. 

A few months later, our customer approached us again inquiring about 

plastic boxes as the metal units were not up to the job. Applying our “can do” attitude, within 3 weeks we had taken the problem, resolved it and now they have plastic fixings and a product that leads the world in its application. 

moulding
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