Case Study: These Product Designers Didn’t Think This Material Would Work – Here’s What We Created

A new potential customer faced a significant challenge with the durability of their equipment hoods, particularly in their construction machinery that operates under harsh conditions year-round. The orange hoods, which were constantly exposed to UV rays, would begin to fade over time, turning a dull, chalky white. Beyond the discoloration, the hoods also needed to endure extreme temperatures—rising to sweltering highs when working outside in the blazing summer heat near hot engine enclosures, and dropping to frigid lows during grueling winter operations. Add to this the constant exposure to dirt, impacts, and heavy wear that construction equipment encounters daily, and the result was a part that simply couldn’t meet the demands of the job.

The customer turned to Plastics Unlimited for help, and we knew we had the perfect solution: our patented TEC (Tooless Engineered Composite) process. This unique technology combines the benefits of two proven materials into a single, high-performing product. The process bonds a tough, thermoformed ABS plastic surface layer to a structural fiberglass backing layer, creating a part that is both incredibly strong and remarkably lightweight.

The benefits were immediately clear:

• The outer ABS surface features a Class A appearance with an acrylic UV-protective layer, ensuring the orange color retains its vibrancy and resists fading, even after prolonged exposure to the sun.
• The fiberglass backing is built to withstand extreme temperatures on both ends of the spectrum—making it the perfect choice for engine enclosures that must survive scorching heat and freezing cold.
• The combined materials result in exceptional durability and impact resistance, standing up to the heavy abuse construction equipment sees on a daily basis.

Not only did our TEC solution solve the customer’s initial challenge, but it exceeded their expectations. The new hoods delivered long-lasting performance, keeping their machinery looking sharp and functioning flawlessly, regardless of conditions. Impressed by the strength, durability, and lightweight properties of the TEC parts, the customer quickly saw an opportunity to improve their overall equipment performance. Over the years, they’ve chosen to transition many more parts to Plastics Unlimited, trusting us to deliver solutions that can stand up to the toughest environments.

This success story demonstrates how Plastics Unlimited’s innovative technology and commitment to problem-solving can transform challenges into long-term partnerships. Our TEC process doesn’t just provide parts—it provides solutions that stand the test of time.

Read More Case Studies