Ross Polymer was commissioned to undertake a comprehensive redesign and manufacturing project aimed at creating a state-of-the-art architectural roofing end cap product. The end caps were destined for extruded profiles and had to be crafted from a technical acrylic polymer material. The project’s primary focus was on meeting stringent product requirements, particularly in terms of dimensional stability and resistance to ultraviolet (UV) light. The undertaking encompassed various phases, including product design, prototyping, tool design, mould flow analysis, tool manufacturing, and an annual production volume of 10,000 units.

Key Objectives and Challenges

Material Excellence
A paramount objective was the careful selection of a technical acrylic polymer material that not only met the product’s structural and aesthetic requirements but also exhibited outstanding dimensional stability and UV resistance. This material choice was pivotal to the project’s success.

Redesign and Innovation
The existing architectural roofing end cap design required a thorough overhaul to align with modern standards and improved performance. The project demanded creative thinking and innovative design to enhance functionality and aesthetics.

Prototyping
Prototyping played a crucial role in the project, allowing for the refinement and validation of the design before full-scale production. This iterative process ensured that the end caps met or exceeded all specifications.

Tool Design and Manufacture
The development of specialized tooling was essential for precise and efficient manufacturing. Meticulous tool design and manufacturing were vital to achieving consistent product quality.