How Dynacast Seamlessly Transferred Safety-Critical Tooling

The Challenge: Ensuring Strict Quality in Safety-Critical Die Cast Tool Transfers

A prominent manufacturer of air brake systems for heavy-duty trucks needed a reliable die casting partner to ensure the continuity and quality of their safety-critical components. With their production reliant on zinc die cast parts, they were faced with several critical tools needing to be transferred with zero disruption to their manufacturing schedule.

The company turned to Dynacast’s Peterborough facility, having previously experienced the team's technical reliability and industry expertise.

The Solution: Expertise, Communication, and Precision Engineering

Dynacast’s longstanding partnership with the customer laid the groundwork for a tooling transfer that was both technically sound and operationally seamless. The project’s success hinged on three pillars:

1. Open Communication and Dedicated Support
   Clear, proactive dialogue ensured alignment between both teams. Dynacast provided continuous technical support throughout the transition, enabling fast decision-making and issue resolution.
2. Flawless Tooling Integration
   The transfer process was meticulously managed, with the tooling relocated directly to the Peterborough site for immediate integration into production.
3. Relentless Focus on Quality
   With safety-critical parts in scope, Dynacast maintained stringent quality standards every step of the way—protecting both performance and customer trust.

Engineering Highlights: Solving for the Unknown

The absence of existing CAD files or tool documentation added complexity to the situation.

The engineering team began with a comprehensive tool assessment, manually evaluating each tool to determine its condition, shot life, and overall suitability for continued use. With no existing CAD data or tool files, this hands-on inspection was critical to ensuring a reliable production setup.

Following the assessment, the team executed a direct facility transfer, transporting the tools straight to Dynacast’s Peterborough facility.

The Outcome: A Smooth Die Cast Tooling Transfer

The tooling transfer was completed successfully and fully integrated into production—without causing any disruption to the customer’s schedule. From the outset, Dynacast maintained the high-quality standards required for safety-critical components, ensuring reliable performance and consistency from day one.