Markets Served

Parts for recreational vehicles and powersports equipment require additional considerations. Aesthetics and functionality are top priorities along with reducing noise, deflecting heat, and preventing moisture and debris from causing damage to components. 

ICP works alongside top recreational and powersports companies to ensure all considerations are accounted for in the design and fabrication process.

Case Study: Splash Guard for Electronic Parts

A client needed a that would act as a splash guard covering an electronic component from getting wet. Our client needed a full-scale solution from design to fabrication, to ensure optimal functionality. Budget and lead time were critical, as the client had no time to waste and needed an effective solution as soon as possible. Our engineering team was then able to make design recommendations for manufacturability, using a die-cut solution.

End results: 

• Shorter lead time – Roughly ½ of the lead time of a thermoformed part.
• Lower tooling cost – Steel rule die was 1/10th of the cost of a water-cooled aluminum forming tool.
• Lower part cost – Part is made with 1 hit of a steel rule die on a piece of plastic.
• Lower shipping cost – parts were able to be shipped in a flat state taking up less space than thermoformed parts that need to be stacked and nested.

Final result: happy client!

ICP designs and fabricates parts for medical equipment that meet performance, safety and quality requirements. We ensure that parts are designed for manufacturability and the materials used will meet the requirements of the application.

Case Study: Automated Endoscope Reprocessing Equipment

A medical company needed a better solution for a vital tool. This company produces Automated Endoscope Reprocessors (AERs), which require parts that are chemical resistant, be sealed tight, and withstand frequent use. They were experiencing several issues with their current part: the fitment of the doors was not smooth, vacuum holes were present on very visible surfaces and their current supplier was not offering much help.

ICP stepped in and worked closely alongside the Original Equipment Manufacturer’s engineers to arrive at solutions for their challenges.

End results: 

• ICP recommended decreasing the starting thickness of plastic to help alleviate the issues with door fitment.  Fit, look, and function were all improved with this process. 
• ICP recommended texturing the mold to assist with hiding the vacuum holes.  The tool side of this part is the visible surface, so vacuum holes will always be present; however, by adding a slight texture, these holes are very well hidden.  This added texture also improved the part to show less scratching, etc. 
• ICP stepped up to the plate and has now become an integral partner with sourcing and engineering on current and future projects by offering design assist engineering as well as manufacturability feedback and process selection. 

Final result: happy client!

Industrial and agricultural equipment has to work hard – ICP works harder. We balance operator safety and ease of use alongside demanding performance requirements, to ensure a superior result.

Case Study: Crenlo Engineered Cabs

We created a fully customized solution for Crenlo Engineered Cabs to streamline their assembly process and reduce unnecessary prep work. Two of the key parts in Crenlo’s assembly process for one of their customer’s applications are their right hand and left hand skirts used on the cab assembly. These skirts are made out of TPO (Thermoplastic PolyOlefin) and mounted onto a truck which is then painted and baked in an oven. In their previous process, the parts would arrive with a residue on them from the prep work at the previous supplier in order to get them ready for painting. 

ICP proposed a newer material from Simona-PMC that includes a directly paintable and bondable film layer in order to alleviate the prep work prior to painting. When the customer receives the parts, they simply do a quick alcohol wipe to clean any potential surface contaminants off prior to painting. 

End results: 

• Cost savings – even with higher-cost materials, the overall part cost is lower due to less prep work at ICP to get these parts ready for paint. Just form, trim, assemble, and ship instead of tying up labor getting parts ready for paint!
• Crenlo was able to save on labor as prep work prior to painting is very minimal.
• Improved cosmetics and lower fallout and rework as the parts are not warping in the oven following paint.
• WIN-WIN for all parties

Final result: happy client!

ICP understands the high degree of precision needed to create parts for vehicles that don’t only perform well under intense conditions – but also look good. We provide an alternative to costly tooling or injection molding solutions to hit that sweet spot of lower cost and higher performance.

Case Study: Airport Rescue Fire Truck

A company that creates airport rescue fire trucks needed to cut truck weight in order to hit their acceleration goals, allowing firefighters to get to crash sites as quickly as possible to save lives. Before coming to ICP, the customer floated a few ideas for weight distribution. Larger engine? No, too bulky and expensive. Store less water? Not an option – the trucks need all the water they can carry.  

We suggested reducing the weight of the truck itself, so that they wouldn’t have to sacrifice engine quality or water storage, yet still achieve faster acceleration.

End results: 

• ICP was able to convert over 20 parts from fiberglass to thermoformed parts greatly assisting in reducing weight of the vehicle. 
• The Airport Rescue Fire Truck exceeded their acceleration goals with the lighter weight thermoformed parts. 
• The process was easily repeatable with thermoformed parts.

Final result: happy client!