Vacuum-formed A, B and C pillar assemblies delivered line-side ready, reducing handling time and supply chain complexity.
Meeting the exacting standards of a Tier 1 automotive supply chain
Our customer required a full suite of interior trim panels, including A, B and C pillars, for a luxury vehicle programme. Each component needed to meet strict dimensional tolerances, carry a premium A surface finish, and arrive at the production line pre-assembled with all fasteners installed. Reducing line-side complexity was a critical requirement — every minute of handling time on a high-value vehicle assembly line has a measurable cost.
Delivering fully sequenced, line-side ready components
We worked closely with the customer's engineering team from the outset, providing Design for Manufacture input to optimise each component for our vacuum forming process. ABS and PC-ABS substrates were selected for their combination of impact resistance and A surface quality. Following forming and 5-axis CNC trimming, each panel moved directly to our dedicated assembly bay where fasteners, clips and foam pads were installed. Components were then packed in bespoke dunnage trays and delivered on a sequenced basis, ready for direct fitment.
A measurable reduction in assembly time and supply chain overhead
By taking ownership of both the forming and assembly stages, we removed a full tier of supply chain complexity for the customer. Components arrived correctly sequenced, pre-assembled, and dimensionally verified — requiring no further handling before fitment. The programme has run across multiple model years and continues to be supplied from our Birmingham facility under IATF 16949 quality controls.
Whether you have a finalised design or a complex engineering challenge, our team is ready to provide the technical expertise and manufacturing precision you need.
