Automotive
Die for gaskets and insulation in automotive interiors
Confidential client ·
A Tier 1 automotive supplier needed strict reproducibility on compound geometries for cabin parts. We delivered a progressive die with serial tolerances of ±0.05 mm.
The challenge
The client produced EVA foam gaskets and acoustic insulation sheets for vehicle interiors with a manual die-cutting process generating a 4% reject rate from geometric drift, and required weekly tooling maintenance.
Our solution
We developed a four-station progressive die with heat-treated blades and EDM-machined positioning guides. Geometry was tuned over two validation rounds with client parts on production material.
Results
Dimensional reject rate below 0.4% in serial production. Tooling maintenance moved from weekly to quarterly. The part passed end-customer PPAP audits on first delivery, with no open non-conformities.
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