Manufacturing Case Studies
Looking for examples of the things we make, and the types of projects our clients incorporate those products into? Our featured thermoforming manufacturing projects will show you exactly that.
We worked with Stratasys, the world's leading 3D printing company to transition from a reaction injection-molded (RIM) to a 100% molded-in-color pressure-formed enclosure. This pressure forming project provided several benefits to Stratasys including improved manufacturing speed. Lastly, this project won gold award in the 2019 Society of Plastic Engineers (SPE) Thermoforming Division Parts Competition.
By switching from in-house sheet metal enclosures to thermoforming with Ray Products, Sunkist was able to develop a next-generation sorter that turns heads at tradeshows, while streamlining manufacturing operations and providing new levels of durability.
By switching from urethane casting to pressure forming with Ray Products, a medical device manufacturer was able to significantly lower costs, improve manufacturing speed, increase durability and guarantee part-to-part repeatability while planning for future increases in demand and capacity.
Goodwill had a goal: to make textile recycling easier, smarter and more appealing than ever. It started by eliminating the trip to a Goodwill location with a donation bin that could live in the lobby of every apartment building in a city. Then, it added advanced wireless sensors that would call for a pickup when the bin was full and a QR code that would generate a receipt for anyone making a donation.
Finally, it went looking for a manufacturing process that could develop an attractive, lightweight, affordable and fully recyclable donation bin. That’s when it found Ray Products.
One of the country’s leading hospital housekeeping management companies was developing a new version of its industry-leading remote vacuum cleaning system. They asked us for our help.
Functionally, this project needed to integrate an industrial vacuum and a UV sterilization compartment into the medical housekeeping cart. Aesthetically, we needed to develop a distinctive style that would help the cart to stand out in a sea of boring beige hospital appliances.
An aircraft parts supplier came to us with a unique challenge. They were being asked to develop a replacement for a part that was last manufactured in 1972. The original molds for the part had long since been destroyed. All we had to work with was a sample part and a full-size drawing from 1972.
To create an exact replacement part, we used a combination of our history with traditional thermoforming practices and some cutting-edge 3D technology.
The individual parts shown here are just 3 pieces in a complex 14-part assembly produced entirely by Ray Products. Producing an assembly of this complexity required precise tolerances and considerable engineering expertise. Throughout the assembly openings in individual parts were molded in first as pockets, then trimmed from the inside to create a highly cosmetic appearance. Individual parts had a variety of assembly hardware attached including thermally installed brass inserts, ball studs, mounting and locating tabs and bosses.
This medical cart incorporates 5 pressure formed parts, all mated to a sheet metal chassis before being shipped to the customer as part of our in-house assembly process. The attachment points are molded into the sidewalls of the parts, to allow for quick and easy attachement to the frame. The formed-in details in the panels showcase our ability to mold highly cosmetic surfaces with tight tolerances.
The design of this medical cart drawer facing incorporated a center recess with a unique finger grab, which allowed for the elimination of handle hardware. The molded-in double "D" feature allows the simple and cost effective installation of a key lock. The edges of the part are turned inward, creating an appealing outward appearance. The inside of the part has 5 bosses with thermally installed inserts attached to allow for easy assembly.
This pressure formed bezel is the public face for a point of sale kiosk. The bezel opening, change dish, card reader and printer features were all molded in place, then trimmed open from the inside surface by our precision 6-axis trimming robots.