Soluciones integrales

Con décadas de éxito sirviendo a algunas de las empresas más exigentes del mundo, el personal de PendaForm tiene el serio compromiso de producir una solución integral que satisfaga sus necesidades específicas.

Trabajando en estrecha colaboración con su equipo, aplicamos conocimientos técnicos de diseño e ingeniería, destrezas de gestión de proyectos comprobadas, una amplia variedad de técnicas de termoformado, numerosos procesos secundarios y otros para ser su proveedor único y ayudarlo a consolidar su cadena de suministro con confianza total.

What's your thermoforming application? Contact PendaForm to get started on a comprehensive system solution today.

Case Study: Cargo Management

Project Facts

Original Process: Blow molded system

Problem: Original process and materials could not hold the dimensional stability required for vehicle assembly.

Solution: PendaForm engineers found ways to hold tighter tolerances, and address concerns missing from the original product, including additional structural ribs and compensation built into the design for better fit up. An added benefit of creating a larger storage area for the consumer.

The PendaForm Partnership

  • Tooling development costs were less expensive with the PendaForm design and it included our engineering team being on site at our customer's location for the entire year of design and development.
  • The project included alternative materials like glass filled polypropylene.
  • An applique made of TPO (painted class A surface) was designed to be attached to the assembly with a hook and tape system on a grained part.
  • Both thermoformed and injection molded parts had matching grain, similar gloss, depth, and texture due to PendaForm's mold design for thermoforming.

Scope

A brand new concept of manufacturing was developed for this customer whose focus was to develop a useful storage system that was accessible from outside of the vehicle and could be utilized for various consumer uses. The main goal was to take advantage of what was previously considered dead space in a truck box, and still have the capability to fit a piece of 4 x 8 plywood in the box.

Open Position
Open Position
Closed Position
Closed Position

Result

The final result was a product delivered on time, within budget. The best testimonial we can receive is that a next generation product is in process.

Case Study: Heavy Truck Interior Bunk

Project Facts

Original Process: Glass filled Polypropylene with reinforced wood and steel.

Problem: Original process and materials were extremely heavy. The cost with another supplier quickly surpassed the original PendaForm estimate, and was not performing to the standard performance requirements.

Solution: Two single sheet ABS skins that encapsulate metal substrates, then are foam filled to complete the assembly.

The PendaForm Partnership

Other design and lower cost criteria met include:

  • PendaForm designed and produces or manages 27 components with 12 different suppliers
  • 2 each thermoforming and injection molding tools as well as 3 foam and 3 glue fixtures
  • Dedicated robotic trim and drill cells which finish all trim and over 3 dozen holes in one process
  • Textured tooling for exterior grain, color gloss (less than 2.5 +/- 1 on a 60 degree gloss meter
  • Low gloss cap layer, co-extruded color in virgin material with a cost savings of utility grade substrate as field of color in gray
  • Reduce the weight of the product from 80 lbs to only 48 lbs and still met all load and deflection targets
  • Metal stampings/hinges, struts to assist lifting efforts

Scope

Over a decade ago, this project was originally lost by PendaForm when the customer chose another vendor with a "less expensive" injection molded design concept. Less than three years later, realizing the current product wasn't meeting cost, quality, or performance level their customers expected.

Exploded View
Exploded View
Assembled View
Assembled View

Result

As an added benefit, the customer was able to reduce the amount of people in their plant from 2 to 1 for installation due to the ease of installation and light weight of PendaForm's design.

Case Study: Heavy Truck Interior Bunk

Project Facts

Original Process: Fiberglass

Problem: Product was heavy and too expensive

Solution: Twin sheet thermoformed ,TPO with aluminum honeycomb and foam filled technology .

The PendaForm Partnership

  • This technology was developed over a decade ago for two key customers. In both cases, these were the first truck covers of their kind.
  • The styled surface, matched texture, water tight bed, also held stringent load requirements.
  • Because of other concepts we had done and our experience to create new manufacturing technology, both customers made PendaForm their chosen single source.
  • The largest challenge in development for these projects was the foam and the aluminum honeycomb insert. They were chosen for strength and low weight of the aluminum honeycomb and the type of foam was designed so that it could flow thru the aluminum structure which made it even stronger.
  • A two year development - from concept to production - with this then new manufacturing technology. Both programs were in production for over 12+ years, the life of the program. These customers have both chosen PendaForm for their next generation vehicles.

Scope

Design and build a hard cover exterior and maintain weather protection.

Tonneau construction
Tonneau construction
Assembled at the plant
Assembled at the plant

Result

High strength and durable - yet light weight, utilizing PendaForm's aluminum honeycomb and foam technology.

Case Study: Cargo Management

Project Facts

Original Process: Wood Board

Problem: Original process and materials were extremely heavy, and were not performing to the standard performance requirements.

Solution: PendaForm engineers were able to remove weight, cost, and a more durable design was ultimately chosen to include HDPE, and encapsulated steel inserts.

The PendaForm Partnership

  • The design team at PendaForm submitted several design concepts to achieve a 20 lbs. weight reduction
  • Using a combination of HDPE, steel, and aluminum the proposed concept was 100% recyclable, as well as being impervious to liquids and biocontaminants.
  • It also happened to reduce the labor needed in the plant to install the PendaForm version of their product, which was an extra, unsolicited benefit.

Scope

PendaForm was approached to design and build a product to replace an existing design that was extremely heavy, costly, and was not recyclable.

Foam Filled Twin Sheet with embedded steel support
Foam Filled Twin Sheet with embedded steel support
Exploded View
Exploded View

Case Study: Commercial Vehicles

Project Facts

Original Process: Various processes, materials, and suppliers managed by the OEM. An aluminum laminated system was considered.

Problem: Alternate proposals could not provide the appearance needed for the market.

Solution: What was once a trend to choose sole sourcing, this practice has become a standard of many of our long term customers, and PendaForm is in the position to deliver.

The PendaForm Partnership

  • Pendaform designed 10 subassemblies. This included over 50 components and 12 sub-suppliers.
  • PendaForm was chosen for this program because of our tooling, supplier relationships, experience with this type of product development, our location, and our willingness to develop new and innovative designs and processes to manufacture.
  • Materials chosen for the best product performance and cost was TPO for the thermoformed components and PC ABS for the injection molded components.
  • Weight savings with increased structural durability was achieved by the twin sheet thermoforming process that is then injected with foam.
  • There were many unique requirements to this program's design, which included several electrical components that were part of the assemblies for functionality of special features and options requiring electrical connection to function.
  • Others distinctive challenges included the twin sheet design to hold the load requirements of the bed floor which replaced an injection molded foam floor with a skin on the top surface.

Scope

PendaForm was tasked to provide a series of sub-assemblies to the plant to build a modular truck box. This project was to include a truck box floor, tailgate, a tonneau cover, side storage boxes, and a buttress airfoil system that provides both styling and aerodynamics. The customer was looking for a sole source for design and assembly, and coordinate all suppliers and component development. PendaForm is a partner that takes responsibility for the entire program.

Result

PendaForm worked closely with multiple departments within our customer's organization. Together, we completed FEA analysis for the component and vehicle levels as well as rapid proto-type model testing to establish product performance prior to making the tool investment. Daily team meetings with PendaForm and the customer occurred throughout development.

Case Study: Cargo Management

Project Facts

Material: Twin Sheet ABS, a telescopic aluminum reinforcement, TPO

Suppliers: In addition to internal production from 1 twin sheet, and 7 single sheet molds, 4 injection molds also were designed, managed by, and became part of the assemblies made at PendaForm.

The PendaForm Partnership

  • Many safety concerns had to be addressed and pass vehicle safety testing, items such as seatbelts while maintaining comfort, and low cost.
  • Materials were chosen for light weight, durability, and to provide a high quality finish.
  • A unique idea was developed by PendaForm enginering for the thermoforming process, a telescoping aluminum frame that actually shrinks with the plastic to maintain durability of the part.
  • Due to the other moving and stowable parts within the lounge, further steel supports were designed and animated to allow the table to rotate down into a stowed position.
  • Other special stampings and metal hardware had also been developed by the PendaForm engineering team to make this product install ready for our customer.

Scope

To create a vehicle interior that would help trucking companies attract and retain new drivers, including more women. They wanted their vehicle to feel like a lounge - with a plush interior for comfort while away from home yet still functional. It needed to have a real bunk, with a real mattress, a functional table with not one, but two comfortable seats. The sleeping area needed to be retractable, stow-able and provide storage.

Result

The final result was a product delivered on time, within budget. This project was a second generation product for our partnership with this customer.