Case Studies
A robotics manufacturer was ready to reject an entire production run of EPDM rubber tubing over visible flow lines and surface inconsistencies. Our engineering team traced the root cause to extruder venting orientation — and eliminated the defects entirely with zero scrap rate. Here’s how we turned a cosmetic rejection into production-ready parts in 48 hours.
PTFE grommets with a low-friction silicone coating sound simple — until demolding micro-tears destroy the coating and kill adhesion. Manual ejection was creating surface defects, slowing cycle times, and driving up scrap rates. We re-engineered both the ejection system and the thermal cycle to deliver flawless coated parts at production speed.
A US lifestyle brand’s premium lunch box was failing airtightness tests right before launch. Some gaskets sealed perfectly, others leaked — the inconsistency was killing production confidence. The previous supplier’s standard compression ratio couldn’t bridge the tolerance gaps in rigid plastic housings. We re-engineered the silicone gasket with precision compression molding and HCR formulation to eliminate every leak.