Metal to Plastic Substitution

Case Study

“They’re very transparent. We know that were pretty demanding, they understand our needs and support us well. Thormac is very collaborative with us.”

When asked if we could replace a metal box with a plastic one.

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 try our best to satisfy our customers and this is what we achieved with this given situation.

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The Solution

We spent over 1 man year and ¼ 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 weel 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.

“They’re very transparent. We know that were pretty demanding, they understand our needs and support us well. Thormac is very collaborative with us.”

“Thormac have engineering expertise, it isn’t just a press a button. They give us confidence.”

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