There isn’t one standard way a project arrives with us. Some customers send us a complete engineering drawing with CAD files, dimensions and tolerances already prepared whereas others have an existing component that has worn out and simply need another one manufactured. We also receive enquiries where the original drawings have been lost, the manufacturer is no longer producing the part, or the only thing available is the component itself.
Each project starts with the information available and we go from there. In many cases that’s enough to begin discussions about the best way forward.
Fit for purpose
Before any manufacturing takes place, it’s important to understand how the component will be used. A floor squeegee blade, for example, needs to maintain consistent contact with a surface during repeated use, while a cable protection component may need to withstand heavy loads and regular impact. Components exposed to water, chemicals, impact or heavy loads will also require different material properties. Understanding the application at the start of the project helps determine both the design and the most appropriate polyurethane formulation.
Where engineering drawings or CAD files are available, these are reviewed before production begins. Those drawings provide the dimensions, tolerances and any technical information needed for manufacture and allow for any queries to be resolved before work starts.
If drawings aren’t available, an existing component can often be used as the starting point. Worn parts can be measured and assessed before new drawings are produced by our in-house designers. Although heavily worn components can sometimes present additional challenges, it’s often possible to establish the original dimensions and recreate the part for manufacture. We are incredibly resourceful and experienced at taking a worn part and creating a usable replacement.
This stage also provides an opportunity to review the existing design. Some customers require an identical replacement because the original component has performed well throughout its service life whereas others are looking to improve durability, reduce wear or overcome a recurring issue. Reviewing the design before production begins allows these changes to be considered before the component enters the manufacturing process.
Material selection is another important part of the process because there isn’t a single type of polyurethane that’s suitable for every job. The grade that’s chosen depends on what the component needs to do as some applications need maximum resistance to wear, while others place more importance on flexibility, impact resistance or the ability to cope with chemicals and heavy loads.
Once the design and material have been agreed, tooling requirements are reviewed. Existing tooling can often be used for repeat orders, while bespoke components or new designs may require tooling to be manufactured before production begins and this is all done in-house in our tool room. Preparing the correct tooling helps achieve consistency throughout the manufacturing process, particularly where ongoing production runs are required.
Not every project follows exactly the same route. Some components move directly into production, while others benefit from a prototype before larger quantities are manufactured. For new designs, we’ll often manufacture a prototype first which gives both us and the customer the chance to check that everything fits and works as expected before a larger batch is produced. If anything needs changing, it’s much easier to do it at this stage.
A final inspection then takes place before dispatch. Depending on the component, this may include dimensional checks and a visual inspection to make sure it’s ready for delivery.
No two enquiries are exactly the same, but the objective remains consistent. Whether we’re manufacturing from detailed engineering drawings, CAD files or an existing component, the aim is to produce a polyurethane solution that’s suitable for its application and manufactured to the standard our customers expect.
Do you need a Replacement Polyurethane Component?
Whether you’re working from an engineering drawing, a CAD file or an existing component, we’re here to help and advise.
We manufacture a wide range of polyurethane products, including:
- Polyurethane rollers
- Polyurethane wheels
- Scrapers
- Seals
- Bushes
- Linings
- Bespoke moulded polyurethane components
- Reverse engineered replacement parts
If you’re not sure whether your component can be reproduced then get in touch. You can send us a drawing, a photograph, CAD file or even the worn part itself. We’ll review what’s available and let you know the most practical way forward.
To discuss a project or request a quotation, contact our experts.