PROJECT DETAILS

Ray Products collaborated with SEKISUI KYDEX to develop an innovative EV Charging Station (DC Block) using new KYDEX® 1100UV material. This case study highlights the challenges, solutions, and successful outcome of this partnership.  

The collaboration between Ray Products, the OEM, and SEKISUI KYDEX originated from a shared vision: to develop a material solution that would exceed the demanding requirements of the DC block housing application in the EV charging sector. With decades of expertise in custom thermoforming and a commitment to solving complex manufacturing challenges, Ray Products took a proactive approach to this project. From the outset, Ray Products recognized the innovation potential not only in material selection but also in advanced processing techniques that would simplify production and reduce costs. 

 

CHALLENGES 

Ray Products’ client previously used various manufacturing processes such as injection molding, structural foam, reaction injection molding (RIM), and sheet metal for their equipment covers. However, they struggled with these methods, either failing to meet the stringent outdoor requirements or with required secondary finishing processes. Specifically, the RIM process fell short of meeting outdoor UL requirements, while sheet metal and structural foam required additional painting, which introduced higher costs and susceptibility to scratching.   

Considering the charging unit contained eleven parts with an average part size of 3’x3′, the client sought a solution with lower tooling costs than injection molding. The project required material that would not only meet the UL746C F1 and V-0 standards but also match the aesthetics of aluminum and withstand UV exposure and severe weather conditions. In addition, the goal was to simplify assembly by minimizing attachment points, which required molded-in features to eliminate the need for secondary bonding of blocks or bosses. 

SOLUTIONS

With a legacy of innovation and a reputation for tackling complex challenges, Ray Products has consistently been a solution-oriented partner to its clients. For over 75 years, Ray Products has specialized in designing custom thermoformed solutions, focused on optimizing material selection, manufacturing processes, and product fitness for use. This customer-centric approach ensures every project is crafted to meet stringent requirements while maximizing quality and durability. 

When Ray Products was approached with the DC Block project, the team leveraged their extensive experience in thermoforming and long-standing partnership with SEKISUI KYDEX. The challenge required a thermoplastic material that could withstand outdoor conditions, meet stringent UL standards, and offer a high-quality, in-mold color finish to eliminate the need for secondary painting. Drawing from its history of identifying and executing the most effective solutions, Ray Products saw an opportunity to elevate the project by utilizing its advanced pressure forming capabilities, 6-axis robotic trimming, and 3D inspection technology. 

To find the right material, Ray Products collaborated with SEKISUI KYDEX’s appLab™ and designLab® Innovation Centers and engaged their R&D teams. Together, they developed KYDEX® 1100UV—an innovative cutting-edge material that meets UL 94 V-0 flammability and UL 746C F1 weather ability requirements while also providing UV resistance and durability in extreme conditions. By employing color measurement software throughout production, Ray Products maintained exceptional color consistency in each part, achieving quality control that would have been more difficult to achieve with painted components. 

RESULTS

Ray Products successfully developed the pressure-formed DC block housing unit using KYDEX® 1100UV, addressing the client’s need for a durable, weather-resistant enclosure that meets stringent aesthetic and functional requirements. The final 11-part enclosure was engineered for easy assembly with minimal attachment points, streamlining installation and eliminating the need for secondary processes. This design approach not only enhanced assembly efficiency but also contributed to the long-term structural integrity and reduced maintenance costs for the client. 

Leveraging the advanced capabilities of pressure forming, Ray Products produced several thousand units with consistent quality, showcasing the effectiveness of KYDEX® 1100UV as a thermoplastic alternative to traditional materials in EV charging unit components. Using KYDEX® 1100UV allowed for greater design freedom, enabling Ray Products to deliver parts with integrated features and an exceptional finish that aligns with the brand and performance standards. 

In keeping with Ray Products’ commitment to high standards of quality and efficiency, the production process included thorough in-line inspections and quality checks, ensuring every unit met the necessary UL certifications for safety and durability. Packaged and shipped directly to installation sites, the DC block enclosures arrive ready for immediate deployment without the need for inspection or repackaging by the OEM – a process improvement that redefines “dock-to-stock” efficiency, saving time and reducing handling costs. 

From material selection to streamlined assembly, Ray Products demonstrated its role as a strategic partner capable of delivering innovative, end-to-end solutions that support the evolving needs of the EV charging market. 

INNOVATING FOR THE FUTURE

Leveraging their state-of-the-art pressure forming technology, Ray Products worked closely with SEKISUI KYDEX to co-develop KYDEX® 1100UV, a thermoplastic material offering unique advantages for outdoor applications. This collaborative effort was guided by Ray Products’ goal to push the boundaries of what’s possible in custom thermoforming, enabling the replacement of traditional materials like metal with durable, aesthetically versatile thermoplastics. The solution aligned perfectly with the OEM’s requirements, offering in-mold color to eliminate the need for painting, improved weatherability, and a high-quality finish—all produced efficiently with Ray Products’ advanced equipment. 

As the market for EV charging stations continues to expand, Ray Products is poised to develop innovative, end-to-end solutions to meet new demands and support the ongoing evolution of electric vehicle infrastructure. The success of the DC block project underscores Ray Products’ ability to adapt and grow alongside emerging markets. With their expertise in high-precision thermoforming, Ray Products is well-positioned to support future advancements in charging station technology, providing faster, more flexible manufacturing options that reduce time-to-market and open new possibilities for product customization. 

In today’s fast-paced world of retail, customer service, and even healthcare, kiosks and point-of-sale (POS) systems play an increasingly important role in enhancing customer experiences and streamlining operations. The design and materials selected for these systems impact durability, functionality, aesthetic appeal, and cost-effectiveness. Traditionally, sheet metal has been the go-to material for these applications. However, custom thermoforming – particularly pressure forming – has emerged as a superior alternative, offering a range of benefits tailored to the kiosk, POS, and even medical industries. As a California-based thermoforming company, Ray Products specializes in solutions that deliver precisely what modern kiosks demand: durability, cost-efficiency, and aesthetic flexibility. Read on to learn why more industries are choosing West Coast plastic thermoforming for their kiosks due to its efficiency, resilience, and alignment with modern design standards. 

Design Flexibility: Thermoforming’s Advantage 

One of the primary advantages of thermoforming over sheet metal lies in its unmatched design flexibility. While sheet metal often struggles to produce intricate designs without extensive secondary processing, thermoforming easily accommodates complex, ergonomic shapes. This flexibility is crucial for kiosks, POS systems, and medical kiosks, which benefit from intuitive designs that enhance user experience, facilitate brand customization, and prioritize user safety. Through pressure forming, Ray Products can create smooth and textured surfaces, integrate undercuts and recessed areas, and include specific design features that enhance functionality and the aesthetic appeal of products in any setting, from retail to healthcare. Pressure forming provides exceptional detail, allowing for crisp features, tight tolerances, and a higher level of surface aesthetics that rival injection molding, making it ideal for sophisticated kiosk designs. Thermoforming offers the freedom to align each system’s look and feel with the customer’s brand image, creating a seamless user interface that metal cannot easily match. 

Cost Efficiency: A Practical Solution 

In addition to superior design potential, heavy-gauge thermoforming offers significant cost savings over sheet metal. The thermoforming process involves heating a plastic sheet until pliable and forming it over a mold for vacuum forming or using pressure forming and pushing the heated sheet into the cavity of a mold. This method is generally less labor-intensive and simpler than the bending, welding, and finishing that is required with metal. For healthcare kiosks and POS systems where budgets are often tight, this streamlined approach reduces production costs and expedites manufacturing. At Ray Products, we offer high-quality molds that reduce the need for secondary operations like painting. Thermoforming provides a durable, cost-effective alternative that meets high production standards across multiple industries, including healthcare. 

Lightweight and Durable: Benefits for Transport and Longevity 

Kiosks and POS systems, especially in medical and retail environments, must withstand constant use while remaining lightweight for easy transport and installation. Thermoformed parts are significantly lighter than traditional metal components, which reduces shipping costs and simplifies on-site assembly. Despite this lighter profile, thermoformed plastics are highly durable, impact-resistant, and able to withstand frequent use in high-traffic areas. Unlike metal, they resist corrosion, making them ideal for high-traffic environments where hygiene and durability are critical, such as hotels, restaurants, hospitals and clinics. We leverage heavy-gauge plastics to create components for kiosks that endure demanding conditions without the maintenance requirements often associated with sheet metal. 

Customization and Branding: Consistency and Quality 

Customization is crucial for making kiosks, POS, and healthcare systems brand-consistent. Thermoforming offers exceptional customization options, enabling companies to add logos, specific color schemes, and textured finishes directly into the molded part. Unlike sheet metal, which typically requires additional coating or painting, thermoformed parts maintain color throughout, ensuring a consistent, high-quality finish that aligns with brand identity. Ray Products excels at providing custom thermoforming solutions that meet each customer’s brand standards, helping them produce kiosks that elevate their brand presence across various sectors, from retail floors to medical lobbies. 

Enhanced User Experience: Clean and Safe Design 

Thermoforming enables the creation of smooth, seamless surfaces that are easy to clean and maintain while also enhancing user safety by eliminating sharp edges. For kiosks and POS systems in healthcare, retail, or hospitality, this results in a user-friendly interface. In medical environments, where hygiene and cleanliness are critical, thermoformed surfaces contribute to a better patient experience by supporting easier cleaning protocols. Thermoforming’s versatility in design ensures that the user experience remains refined, intuitive, and consistent across applications. 

Sustainable and Environmentally Responsible 

As the push for sustainability grows across industries, thermoforming offers clear advantages over traditional metal. The process generates less waste, with excess material often recycled, reducing environmental impact. As a California-based thermoforming leader, Ray Products prioritizes sustainable manufacturing practices by using recyclable, durable thermoplastics, contributing to an eco-friendly production cycle. For manufacturers looking to support environmental responsibility – whether in retail, medical, or other sectors – thermoforming offers an eco-conscious solution that aligns with today’s standards. 

Faster Time-to-Market 

In a world where quick response to consumer and industry demands is essential, thermoforming offers shorter lead times than sheet metal. Thermoforming molds are quicker to produce and easier to modify, which speeds up prototyping and production. Ray Products excels in delivering thermoforming services that support faster time-to-market, ensuring that kiosks remain up to date with the latest technology and design trends. This adaptability is invaluable for companies aiming to stay competitive and responsive to changing market needs. 

Takeaways 

As the demand for innovative, durable, and customer-friendly kiosks and POS systems grows across retail and healthcare, thermoforming emerges as a robust alternative to traditional sheet metal. With superior design flexibility, cost-effectiveness, and sustainability, thermoforming meets the practical and aesthetic demands of these markets. Ray Products is a custom thermoformer committed to providing industries with high-quality, efficient thermoforming solutions that elevate customer interactions and streamline operations. 

By choosing thermoforming, businesses in all sectors – from retail to healthcare – can enhance their kiosk designs, reduce costs, and support sustainability. If you’re looking for a company on the West Coast in the thermoforming industry with expertise in custom kiosk and POS solutions, contact us today to learn how our custom thermoforming services can elevate your kiosk projects with quality that stands the test of time. 

 

As a third-generation, family-owned manufacturer offering advanced thermoforming solutions, Ray Products is committed to staying at the forefront of industry knowledge and trends. We attended this year’s SPE Thermoforming Conference in Cleveland, Ohio, October 24-26, to learn about the latest innovations in thermoforming machinery, materials, and equipment. President Brian Ray reflects on this year’s conference and discusses the impact it is poised to have on the company’s future endeavors and the evolving landscape of thermoforming as a whole.

Q: What was your biggest takeaway from attending the 2023 SPE Thermoforming Conference?

A: “I’m always amazed at the advances made in our industry. The shared focus on elevating the process and the willingness to discuss best practices is refreshing.”

Q: What significant advancements in thermoforming were discussed at the conference?

A: “I was really impressed with the amount of high-level assembly being done within our industry. It’s not just custom molding of plastic parts anymore – it’s high-level, complex assemblies incorporating various processes coming together to provide a finished part solution for customers.”

Q: What current challenges facing the thermoforming industry were discussed, and how does Ray Products plan to address them to maintain its competitive edge?

A: “The cost of manufacturing – regardless of industry – is a constant challenge. We’re based in California, so we’re no stranger to manufacturing challenges; that’s why we focus so much on automation, employee training, and early customer involvement. With so many manufacturing choices, we need to make sure we listen to our customers, understand what they want, and determine if our process is the best fit to satisfy those customer requirements.”

Q: What were the key discussions and impressions during your interactions with industry professionals at the conference?

A: “We spent a lot of time with various tooling manufacturers, discussing more automated solutions for formed-in features like undercuts, better surface finishes for molded-in texture and reduced lead times. We were also impressed with the prototype services offered by various vendors at the show. From a materials standpoint, the number of thermoplastics being offered that can solve many issues other processes face is remarkable. There are numerous solutions for high-impact, chemical-resistant, fire-rated, recyclable, high-heat materials that won’t scratch or dent, can be bonded and color-matched, have low surface energy, and meet UL V-0 and 746C regulations. The possibilities are endless.”

Q:  Did anything catch your eye at the conference as a potential asset for enhancing Ray Products’ current capabilities?

A: “Anything that can reduce set-up or cycle times has my attention. Quick change systems for tooling and clamp frame systems that easily adjust were a talking point. Automation was a huge topic, not just for material handling and secondary operations, but the impact AI and machine learning will have on our industry.”

Q: This year’s conference theme was “The Business of Thermoforming.” What key strategies do you foresee implementing to ensure Ray Products remains at the forefront of the thermoforming industry?

A: “A continued push to measure and improve. Sometimes we get stuck in the weeds of our day-to-day operations, and this conference provides so much additional perspective that I always leave with fresh insights and actionable strategies that can be implemented to improve our business.

Additionally, industry and processing knowledge are critical to success. Therefore, we need to be better at documenting what we have and elevating our employees to become the next generation of leaders within our industry.”

Q: Are there any final thoughts you’d like to share about the conference?

A: “With so many ways to communicate and access information, we can easily forget how important a face-to-face conversation can be, as well firsthand experiences like holding a sample part, touching a prototype tool, or seeing oven heating technology up close and in person. This year’s conference was an amazing experience, and I especially enjoyed the panel discussions, which are a great way to share and exchange best practices.”

President Brian Ray’s insights from the 2023 SPE Thermoforming Conference illuminate our commitment to industry leadership. Armed with a fresh perspective and newfound knowledge, Ray Products is geared to navigate challenges, embrace innovation, and shape the future of thermoforming. If you’re ready to start your thermoforming journey with us, contact us today!