Case Studies

An illustrative diagnostic study for deep-rib burn marks: inspect the air-escape path, separate competing causes, plan controlled trials and retain cavity-specific evidence.

An illustrative engineering study of EV battery cell spacer design: material evidence, insulation boundaries, checked tolerance examples, molded-fit validation and release records.

An illustrative engineering study for polypropylene living hinge design, covering material selection, hinge geometry, gate and flow analysis, and a reproducible fatigue test plan.

An illustrative engineering study for defining, testing, and diagnosing threaded insert pull-out strength in injection-molded plastic housings.

An illustrative engineering case study showing how asymmetric punch-to-die clearance can be investigated without destroying evidence through premature regrinding.

A stamping plant running 40 progressive dies from several toolmakers lost dozens of press hours a month waiting for broken punches and inserts. A die spare parts program built on reverse engineered drawings, criticality ranking and shelf kits cut that downtime by 63%.

An automotive sensor housing with insert-molded terminals was failing leak tests after thermal shock. Failure analysis, a redesigned lead frame, a new gate and a heated, clean insert process brought failures down from 4.1% to 0.05%.

A medical device OEM was hand-trimming flash from a silicone check valve made in an 8-cavity tool. Our 32-cavity cold runner LSR mold removed the trimming, cut the cycle to 22 seconds and multiplied output more than six times.

A fuel cell stack developer’s metallic bipolar plate was cracking at the channel corners and failing flatness. A two-stage forming die, new radii and a calibrated process fixed cracking, thinning and depth variation for the pilot line.

An automotive connector maker needed four times the output from its terminal stamping line and a capable process for PPAP. This is how our die team redesigned the strip, coined the contact zone and got there in eleven weeks.