Johnson Controls wanted to create a highly aesthetic interior trim piece for a low volume vehicle - the Dodge Viper. The new part had to replicate injection-molded features in a large one-piece part while maintaining a lower cost tooled solution that maximized their investment. Further, the part had very tight dimensional tolerances on a very low volume production vehicle where injection molding would have presented cost and process challenges.
Everbrite created an intricately engineered pressure formed solution that featured undercuts and very tight tolerance details. CNC trimming allowed for multiple changes without costly tooling reworks during development and launch. Everbrite's solution is more cost effective (from a total cost of ownership standpoint) than the alternative injection molding, and maintained a stable and reliable process geared toward low volume production (less than 3000 annually).