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Case Study: High Precision PET Die-Cuts for Automated Assembly Success
Delivering Parts that Surpassed Tolerance Requirements and Reduced Waste for a Critical Battery Pack Project
"Our customer had invested in high-speed automated application equipment to apply a self-adhesive die-cut. Unfortunately, their existing part supplier was unable to achieve the level of die-cutting accuracy required for the equipment to function. The project and investment were at maximum risk.
We specified a new material, re-designed the tooling, and supported with the automation process. The result was immediate equipment sign-off, scrap reduction from over 10% to 1–2%, >10% output increase, cost savings, and restored confidence. Our new customer and the automation equipment supplier were both delighted with the rapid resolution and the improvements that came with it."
Kevin Porter, Technical Director
Part Inconsistencies Leading to Delays & Waste
1. The Challenge
We were engaged to support on a critical battery pack component project involving the high-speed automated application of large die-cut PET parts onto machined aluminum components.
A previous supplier had struggled to achieve the tight tolerances required, resulting in dimensional and placement inconsistencies across the PET die-cuts and placement onto the aluminium components. These variations caused misalignment during automated placement, triggering application errors and downstream process failures.
Crucially, this led to a delay in the sign-off of the automated application equipment. As a result, aluminium components had to be scrapped during testing, increasing material waste, raising costs and leading to concerns about the automated process.
Enhancing the Part and Surpassing Expectations
2. The Solution
We initiated the project with a thorough on-site investigation, visiting both the customer’s facility and the developer of the automated application machine. This was critical for gaining a complete understanding of the precise requirements for the die-cut PET parts and the constraints of the high-speed automated process. We also conducted analysis of the previous parts and extensive material and adhesive testing.
Following this discovery work we identified and implemented fundamental changes to the part specification:
- Carrier Material: Switching the material to one we could precisely retune for performance and stability.
- Adhesive System: Selecting a new adhesive and release liner combination specifically for superior compatibility with the high-speed automated process.
- Tooling Optimisation: Collaborating with the toolmaker to refine the die-cut tool and further solve compatibility issues with the application process.
- Application System Improvement: By adding our knowledge of automation, we were able to suggest some improvements to the Application Equipment which resulted in significant increase in output
This combined approach enabled us to develop and manufacture high-performance PET die-cuts that not only met the customer’s very tight tolerances but significantly surpassed requirements, achieving dimensional consistency twice as tight as the required threshold.
Production Success
3. The Outcomes
The successful development and production of the improved, high-performance die-cut PET parts yielded immediate and measurable results for our customer:
- Production Success: By manufacturing parts that consistently surpass the tight tolerance thresholds, the automated application process was able to run at high-speed with precise placement of the large part on the aluminium components. Leading to the immediate sign-off of the automated application equipment, allowing rapid progression to full-scale production.
- Scrap Reduction: The customer’s material scrap rate was dramatically reduced from over 10% to between 1% and 2%, successfully reducing waste by up to five times and generating significant cost savings.
- Increased Output: The customer was able to increase output by over 10% through the implementation of some design suggestions from our engineering team.
Our involvement in the project, to improve the die-cut PET part design and specification, delivered high-performance manufacturing success and restored business confidence in the project.
Results of the Project:
Why did the customer choose Tecman?
Facing unacceptable scrap rates and delays caused by inconsistent parts, we were invited to add our expertise to the project. They needed a partner who could address not just the part quality and performance, but compatibility with the automated application system.
Impressed by our proactive, investigative approach, visiting both their facility and the machine developer, and our capability to redesign and improve the part specification to achieve dimensional consistency twice as tight as required. The customer trusted us to help achieve project success and move to full production.
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.
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