Campervan Roof Manufacturers
The journey from hand lay-up to Direct Infusion
Background
Based in the UK, our client is a leading manufacturer of campervan elevating roofs (pop tops), with roof fitters operating throughout the UK and Europe. They manufacture roofs for VW, Ford, Renault, Vauxhall and Nissan Vans.
All production is handled in-house, and their products are TUV safety-tested in the TUV Rheinland testing facility in Cologne.
When our client first approached us, they were still hand-laying their composites, using highly skilled operators.
Challenge
Our client had a unique reverse tool design, but were still hand-laying all of their production.
Hand-laying is:
- Time-consuming
- Wasteful, with a low yield
- Hazardous
- Labour-intensive
- Reliant on hard-to-source expertise.
Our client asked:
- Can we develop and scale a safer and more efficient process?
- Can automation cater to our unique tool design specifications?
- Can we save weight and minimise waste?
- Can we do this whilst maintaining profitability?
Solution
Working closely with our client, our CI experts:
- Analysed their tool design, and current production requirements.
- Scoped an automated RTM process to meet their requirements.
- Specified a CIJECT 1 machine, vacuum pump and RTM version of their reverse tooling.
- Supported them in manufacturing their first parts, helping them configure the process around the prototype.
- Installed and calibrated the production solution onsite.
- Trained their staff, equipping them with the skills, knowledge, and confidence to continue the process independently.
Results
Our client has:
- Scaled production
- Improved quality
- Reduced product weight
- Increased consistency and reliability
- Increased yield
- Reduced materials waste
- Reduced costs
- Created a safer production environment
“The CI team experts supported us in our journey to RTM production, integrating our unique tooling design into the process. With our CIJECT machine we can now profitably produce high quality parts at scale, consistently and reliably.”