How this solar company leveraged tax incentives through onshoring

The challenge: A race against time and quality

Faced with new federal incentives aimed at reshoring production to the U.S., a leading solar mounting system manufacturer encountered a major roadblock. Their previous die casting supplier couldn't deliver the speed, quality, or production volume needed to capitalise on the opportunity. Poor production output, neglected tool maintenance, and lack of support put both the project timeline and valuable tax incentives at risk.

The objective: Onshore, scale, and elevate quality

The customer's goals were clear: move production to the U.S., improve component quality, and ramp up capacity to meet a growing market. But meeting these targets meant overcoming the obstacles of a struggling supplier and executing a tooling transfer that wouldn't disrupt the manufacturing timeline.

The solution: A strategic partnership built for performance

The Dynacast team quickly developed a plan to bring the customer's programme back on track.

Dynacast prioritised a rapid, quality-driven onshoring process, recognising the urgency of the situation. The team executed a seamless tooling transfer and ramped up production, enabling the immediate delivery of high-quality parts from day one.

In addition, supply chain simplification was a key focus. Dynacast offered a range of value-added services, including in-house assembly, custom fixtures, and specialised packaging.

Engineering in action: From on-site visits to Dynacast Lake Forest

The success of this transition hinged on careful engineering and collaboration:

• A hands-on, collaborative approach: Dynacast's Lake Forest engineering team worked closely with the customer's technical staff to understand exact product and tooling requirements. The process began with an on-site review at the outgoing supplier's facility and continued with a detailed inspection once the tools arrived at Dynacast.
• Expert tool refurbishment & integration: The tools were thoroughly cleaned, refurbished, and, where needed, modified to suit Dynacast's production environment. This careful preparation ensured a smooth handoff with minimal production disruption.

The results: Onshoring success with room to grow

The solar manufacturer successfully moved production to the U.S., qualifying for tax incentives and dramatically improving part quality. Beyond immediate gains, the company also laid the groundwork for broader reshoring initiatives.