Case Study: Protection Film Die-Cut Prevents Transport Damage

Rapid Development of a Custom Surface Protection Component for the EV Supply Chain

"Our customer's product was on the verge of full production when early runs revealed an issue: transportation was causing scratches and damage. We were asked to quickly develop a protection film solution to prevent this damage and seamlessly fit into their existing processes. The customer was extremely pleased with the final component and it was a genuine pleasure to help them overcome this challenge.”

Wayne Matthews, Tecman Project Lead

Protecting Delicate Matt Surfaces During Transportation

1. The Challenge

A manufacturer within the EV charger supply chain faced a critical problem: their product parts were incurring damage during transportation. Specifically, components were moving in transport, leading to scratches on a matt-finish substrate — a crucial element for the final product's attractive aesthetic. 

After exploring various options, the customer determined that a custom temporary protection film component offered the quickest and most effective solution. They turned to Tecman for a robust protection film solution that would completely eliminate transportation damage while ensuring they could still meet their strict production and delivery schedules. 

The solution needed to meet several other key requirements: 

  • Perfectly conform to the complex geometry of the product's surface. 
  • Leave no adhesive residue upon removal. 
  • Add no extra time to the existing production process. 

Developing a Custom Die-cut Protection Component

2. The Solution

To provide the most effective support, we immediately visited the customer's site. This allowed us to observe their manufacturing process firsthand, directly examine the product, and assess the damage to truly understand the challenge. 

2.1 Selecting the ideal protection film for the project 

The textured matt substrate of the product required a protection film with a particular level of tackiness: a sufficient tackiness to adhere sufficiently to withstand friction from moving parts during transport, yet crucially, leave zero adhesive residue upon removal by the customer. 

Leveraging our deep expertise in adhesives and materials, we swiftly identified a suitable protection film that performed exceptionally on the matt substrate. We were able to dispatch the first prototypes the very next day after receiving the initial enquiry. 

2.2 Designing a Custom Die-Cut Component 

As with all our projects, we dedicated time to fully understand the customer's specific challenges and identify opportunities to add significant value to their processes and final product, building these insights into the part design. 

Collaborating closely with the customer, we pinpointed a small window within their existing manufacturing process where the die-cut protection film could be applied. We then added features into the design to enable effective and accurate application of the part in just seconds, ensuring no risk of delays to the production line.   

To perfectly conform to the product's complex geometry, we divided the protection film into a small number of sections. We also incorporated additional design features to guarantee optimal and complete surface coverage with every application. 

 

Surface Protection Film

 

 

 

 

 

Surpassing Expectations with Custom Die-Cut Surface Protection

3. The Outcome

Tecman's custom die-cut surface protection solution delivered precisely what the customer needed, eliminating all transportation-related part damage. Our quick and responsive service enabled the customer to meet their original production and delivery schedules without interruption.

Additionally, our Tecman protection film component enabled complete protection of the product’s surfaces with a fast application process that fit seamlessly within the existing manufacturing process.

Results of the project:

  • Protection
    Eliminated transport damage
  • Tick
    Integrated into existing processes
  • Tick
    Enabled timelines to be met
  • Ico Transfer
    Temporary film with no residue

Why did the customer choose Tecman?

Harging Vehicle Resized

Faced with unexpected product damage during transportation and a tight production schedule, the customer needed a proven partner who could deliver a rapid, custom solution. Tecman's proven expertise in custom surface protection components and solution-driven approach made Tecman the ideal choice. 

Our ability to select the right protection film for the challenging substrate, coupled with our collaborative approach to designing a precise, die-cut component, delivered tangible value where it mattered. Our focus on seamlessly integrating the solution into their existing manufacturing process ensured a cost-effective and efficient outcome that eliminated damage without disrupting their deadlines. 

Discuss your project with Tecman

We support our customers through every stage, from material selection and design phases to choosing the right manufacturing processes. This ensures the delivery of an optimised, cost-effective solution designed to effectively overcome challenges and deliver tangible benefits. 

If your application could benefit from cost savings, process improvements, material enhancements, and product advancements, reach out to our experts to discover how we can support your application. 

Get in touch to discover how we can support your needs

Industry-leading custom engineered components

Delivering value precisely where it matters

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