Challenge:
The foam seals required by heavy equipment OEMs presented some challenges for our team.
First of all, some seals must be very thick. Some of the larger seals have to reach a thickness of 90 mm, which is thicker than the raw materials available. The OEM and we determined that multiple layers could be stacked together to create a seal thick enough to meet their needs. This leads to a second obstacle, which is that any adhesive designed to be used for laminating purposes in a seal needs to be thoroughly tested before manufacturing begins.
Adhesives also have special requirements. These parts will be subjected to high and low temperatures, exposed to ultraviolet light, and some will adhere to low surface energy substrate molded plastics. We worked diligently to meet adhesive needs and created several test samples working towards approving the best adhesive selection.
The third unique challenge is that the OEM requires several rounds of samples, and the prototype seal must pass a series of trials and tests conducted by the OEM.
When Sealpilot first received an OEM's request and looked at the request, they immediately knew the ideal material for the seal, which is known for its superior sealing properties.
Solution:
In order to manufacture the foam seals required by heavy equipment OEMs, we work with the OEM's engineering team to select the appropriate foams and adhesives according to the customer's specifications and develop a satisfactory lamination process to manufacture the required thickness. After sending a series of samples to OEMs so they could test the adhesive, Sealpilot was granted green clearance and began production based on weekly orders from OEMs.
First, the cut foam rolls are laminated together to produce the desired thickness, ranging from 5mm to 90mm. Next, a pressure-sensitive adhesive (PSA) is laminated onto the foam to provide a way to attach the part to the customer's substrate. Finally, the parts are cut using the die-cutting process or water jet cutting.
In total, the customer needed more than 100 unique parts for the multiple pieces of equipment they manufactured. We ship multiple shipments to multiple factories every week. Parts are packaged in custom tote bags, barcoded with custom labels, and shipped in precise quantities in each tote bag.
