MANUFACTURING CASE STUDIES

This handling tote is custom manufactured to increase productivity on a manufacturing assembly line. Each tote is vacuum formed over a male mold, then trimmed and packaged by Ray Products. Our low tooling and parts costs allow this customer to create handling totes in many custom configurations.

These Solar Collector Modules are made from color matched weatherable ABS, designed to withstand UV light and provide impact protection in harsh outdoor environments. As part of a precision assembly, this project required a high amount of detail and precision, and each module was created with extremely close tolerances.

In this next-generation DNA sequencer, Ray Products manufactured 10 pressure formed parts that came together to create an aesthetically appealing enclosure.

This recycling bin lid allows for easy recycling and separation of paper, bottles and cans. Used in outdoor environments, the part needed to be tough. The rugged material selection is complimented by molded-in ribs in both the length and width of the lid that increase the overall strength of the part, while keeping its overall weight low.

This pressure formed bezel is the public face for a point of sale kiosk. The bezel opening, change dish, card reader and printer features were all molded in place, then trimmed open from the inside surface by our precision 6-axis trimming robots.

The design of this medical cart drawer facing incorporated a center recess with a unique finger grab, which allowed for the elimination of handle hardware. The molded-in double "D" feature allows the simple and cost effective installation of a key lock. The edges of the part are turned inward, creating an appealing outward appearance. The inside of the part has 5 bosses with thermally installed inserts attached to allow for easy assembly.

This medical cart incorporates 5 pressure formed parts, all mated to a sheet metal chassis before being shipped to the customer as part of our in-house assembly process. The attachment points are molded into the sidewalls of the parts, to allow for quick and easy attachement to the frame. The formed-in details in the panels showcase our ability to mold highly cosmetic surfaces with tight tolerances.

The individual parts shown here are just 3 pieces in a complex 14-part assembly produced entirely by Ray Products. Producing an assembly of this complexity required precise tolerances and considerable engineering expertise. Throughout the assembly openings in individual parts were molded in first as pockets, then trimmed from the inside to create a highly cosmetic appearance. Individual parts had a variety of assembly hardware attached including thermally installed brass inserts, ball studs, mounting and locating tabs and bosses.

An aircraft parts supplier came to us with a unique challenge. They were being asked to develop a replacement for a part that was last manufactured in 1972. The original molds for the part had long since been destroyed. All we had to work with was a sample part and a full-size drawing from 1972.

To create an exact replacement part, we used a combination of our history with traditional thermoforming practices and some cutting-edge 3D technology.