Case Studies | Poly Evolution

Automotive Tier 1

Reduced material cost 18% on interior trim component via PP compound reformulation

18%

Reduction in material cost per kilogram — achieved without specification downgrade or tooling modification

Problem

Commodity PP grade over-specified for application; margin pressure on high-volume program

Solution

Custom PP-talc compound reformulated to match mechanical properties at lower raw material cost

Customer was running a Tier 1-specified glass-filled PP on a door trim substrate that didn't require glass fiber reinforcement — just stiffness and a class A surface. We reformulated with a talc-filled PP compound that met the dimensional and impact spec at significantly lower additive cost. Validated against the OEM test protocol and qualified within 6 weeks.

Medical Device

FDA-compliant compound sourced and qualified in 6 weeks for production launch

6wk

From specification to production-qualified material — 40% faster than the customer's previous vendor benchmark

Problem

Launch timeline at risk after primary material supplier could not provide FDA 510(k) documentation in time

Solution

Identified equivalent ABS grade with full FDA documentation trail; validated equivalence with customer's QA team

A diagnostics device manufacturer needed a replacement ABS source after their qualified supplier's lead time pushed past the launch window. We identified an equivalent grade, pulled the full 510(k) documentation package, and ran equivalence testing against the customer's incoming inspection protocol. Material was production-qualified before the original supplier could respond with a revised date.

Industrial Equipment

Switched from machined steel to fiber-reinforced nylon — 34% part weight reduction, maintained load spec

34%

Part weight reduction achieved while meeting the original static load and wear-resistance specification

Problem

Machined aluminum bracket adding excess weight to a mobile equipment platform; customer exploring plastic substitution

Solution

GF30 Nylon 66 specified and validated through FEA-correlated physical testing; injection mold tooled for production volume

An industrial equipment OEM needed to reduce platform weight to meet new DOT axle rating requirements without redesigning the chassis. We evaluated the load path on a structural bracket assembly and recommended GF30 Nylon 66 as the substitution candidate. After FEA modeling confirmed feasibility, we supplied material for prototype tooling and validated final parts through the customer's accelerated life test.

Consumer Electronics

Custom color-matched ABS qualified across 3 global production sites for retail packaging insert program

3

Production sites qualified on the same compound specification — one source, consistent appearance across markets

Problem

Different ABS grades at each production site producing visible color variation in a high-visibility retail package insert

Solution

Single custom-compounded ABS grade with standardized colorant, supplied to all three sites through regional distribution partners

A consumer electronics brand was producing a branded packaging insert at three injection mold sites across two continents — and the parts were visibly different colors on the retail shelf. We developed a custom ABS compound with a Pantone-matched colorant system and a locked lot protocol, then coordinated supply through partner distributors in the US, EU, and Asia to ensure consistent material at all sites simultaneously.

Real results.
Real materials.

The problem, the material, the result.

Tell us what you're trying to solve.

Real results.Real materials.

The problem, the material, the result.

Tell us what you're trying to solve.

Real results.
Real materials.