MWR developed a dip molding process using automated manufacturing equipment, custom designed and built in-house, that achieved the desired cost efficiencies. Part engineering by MWR personnel improved the blade hood’s finish and appearance. MWR was also able to execute subtle tooling design changes to satisfy evolving client needs.

MWR’s proprietary dip-molding process was perfect for this specialized cushion. MWR was able to quickly create a sample part that exceeded the client’s rigid specs and received permission to begin production.

MWR designed, through trial and error, a uniquely designed bellows system to produce the appropriate volume of air via foot pressure to create the sound, while also using materials that would work within a wide range of temperatures and weather conditions.

MWR engineers developed different materials for both the core and surface components of the cushion. The processes were unique in application, but MWR was able to marry the two components successfully, achieving 100% client satisfaction.

By using the customer’s existing shift boot as a base, which was the same size required for the new part, MWR engineers designed the new extension as an additional part that could be permanently attached to the current shift boot base in a final assembly step. Thus, tooling costs were kept to a minimum and the manufacturing costs of the extension were well within the client’s budget target.

MWR proposed a boot cover (instead of a flexing boot design) that would cover the clutch lever up to and including the pivot point, which effectively eliminated the failure mode. This redesign, which varied from the original proposal, also allowed for future vehicle build variations, a plus for the client.

MWR engineers created a leather-like shift boot using the slush molded process. The recreation of the leather grain and stitching was so authentic it fooled automotive reviewers and focus group participants.

During engineering development of the one-piece bun MWR did more than reduce the overall cost of the replacement. Additional engineering enhancements that could not have been accomplished with the existing die cut process enabled a number of additional improvements. MWR was able to cut the prototype foam molds in-house for quick turn around, and cycle-durability and heat-age testing was done in-house.

Our first thought was foam molding this part instead of die cutting, folding and gluing. Upon further research on the vehicle’s interior, we learned that the servicemen would occasionally use the flat area in the interior as a step to climb in-and-out of the vehicle. Almost any foam part, whether its die cut or molded wouldn’t hold up to this usage. Armed with this knowledge, we advised the customer to consider a rubber cover/step, a very durable part that could hold up in the long run.

MWR engineers first created a 3-D solid model of the part. Once approved, we used the 3-D model of the part to create a model for the tooling. From here we created and verified the tool paths for our CNC Router and cut the tooling in-house. With the tooling finished and verified we produced the parts using our rubber dipping process.