How Dynacast orchestrated a complex tooling move

The challenge: plant closure creates a complex task

When a long-established plant closed, a leading company in the security products industry faced an urgent and complex transition. The facility's ageing infrastructure, high labour costs and inefficient tooling utilisation had made in-house production unsustainable. With most of the tooling contributing minimally to overall production spend, the decision was made to relocate dozens of tools—an ambitious undertaking requiring speed, coordination and technical precision.

However, the path ahead was not straightforward. Rising cost pressures, logistical strain from shipping dozens of tools each month and unclear tooling documentation posed genuine threats to success. In addition, inconsistent sampling protocols and missing information for secondary operations risked slowing the process.

The solution: a smart shift towards efficiency and control

Dynacast's focus was not simply on moving die casting tools—it was on optimising them for improved performance and establishing a foundation for long-term value.

Dynacast brought extensive expertise in precision casting, applying an engineering-first approach to ensure every part was carefully engineered and accurately cast for optimal performance. This technical rigour was matched by speed without compromise—the team acted quickly to meet demanding timelines without compromising quality, maintaining the highest quality standards throughout. However, what truly distinguished the project was the partnership dynamic.

The implementation: prioritising medium- to low-volume parts

Thanks to compatibility with the customer's existing equipment platforms, the Dynacast team was able to integrate the transferred tools with minimal disruption—often bringing the die casting machines into operation within a day or two. Dynacast focused its efforts where they mattered most: medium- to low-volume parts offering the greatest strategic value, while also keeping future high-volume opportunities in view.

Capabilities that matter

The equipment used at Dynacast represented a major upgrade from the ageing machines of previous suppliers. Our ability to build both tools and machines in-house gave the team unique control over quality and lead times. When additional flexibility was required, our collaboration with global teams—including engineering support from Asia—ensured that progress was not delayed.

The results: partnership, performance and future potential

Weekly check-ins, pilot runs and a commitment to shared success laid the foundation for a lasting strategic relationship. By avoiding supply chain disruptions during a critical transition, Dynacast not only ensured continuity but also improved tooling performance—extending tool life and setting the stage for future growth and opportunities.