After thorough consultation and review, Evans Evco found the perfect solution in the form of die-cut LDPE protective tape.

Using the samples of the rejected reflectors the tier supplier provided, as well as reviewing a variety of material samples from our tape supplier, we were able to quickly identify an LDPE protective tape having a low-tack removable rubber adhesive which had the required elastic properties needed to perfectly conform to the reflector shape.

Additionally, due to the type of material, quantities needed, and the various shipping and handling requirements, we decided to use a rotary die-cutting process with a mixture of slitting, rewinding and cold laminating capabilities. 

With the help of our tooling supplier, the final dimensions were measured to a tolerance of ± .002” which was within specification, and they were also able to engrave micro perforations so the assembly crew at the automotive OEM could fasten the reflector to the car without removing the whole die-cut piece.

Furthermore, we opted for a C1S rigid liner, which allowed the workers to remove the die-cut piece without removing their cotton gloves. 

RESULTS: Salvaged Parts, Salvaged Relationships  

Before we were involved, the tier supplier was at risk of being de-certified by the automotive OEM due to production rejections reaching 27%, and OEM rejections reaching 32%.

We are proud to say that through collaboration with our suppliers and full utilization of our converting capabilities, Evans Evco was able to completely eliminate cosmetic damage to the reflectors from production to attachment.

Most noticeably, since the successful completion of this project, the tier supplier has been able to use this process on other reflector products they produce for other automotive OEMs with the same success