With the supplier unable to meet cost and weight limits, our solution was the result of a hybrid thermoforming/compression process using a custom-built forming machine, along with a unique spray and curing operation. Neither waterjet nor router trimming were going to work either, necessitating the use of a custom-built flying knife system attached to our robotic router arms.
Amazingly, it took only six months from first contact to the shipping of final product and the parts that were delivered came in at budget and within weight parameters.
