Summary: Fairway Products, an expert in textile and material conversion, partnered with a leading outdoor solutions provider to deliver high-quality RV screens. This project entailed die-cutting aluminum screens and attaching them to molded plastic frames through an innovative heat-staking process. The resulting product met stringent quality standards and was seamlessly integrated into the customer’s assembly line, demonstrating Fairway’s capabilities in precision manufacturing and value-added services.Project Specifications
Uses and Applications
The RV screens manufactured in this project are designed for installation in recreational vehicles, providing durable and reliable screening solutions. These screens are essential components for RV windows, ensuring ventilation while keeping insects and debris out.
Scalability of the Project
The initial run of this project demonstrated Fairway Products’ ability to scale production efficiently. Starting with a pilot batch, the process was refined and optimized to handle larger volumes, ensuring consistent quality and timely delivery. The scalability of the project underscores Fairway’s capability to meet increasing demands without compromising on precision or performance.
Manufacturing Process
Die-Cutting
Rolls of aluminum screen are processed through a die-cut machine to achieve the required shapes.
Refrigeration of Frames
Molded plastic frames are chilled using a refrigerated unit to ensure precise expansion during the heat-staking process.
Heat-Staking
The die-cut screens are heat-staked to the chilled plastic frames. As the frames return to room temperature, they expand slightly, ensuring the screens remain taut and wrinkle-free.
Quality Control
Each RV screen undergoes rigorous quality checks to ensure adherence to specifications and ISO 9001:2015 standards.
Quality Control Steps
Fairway Products adheres to strict quality control measures throughout the manufacturing process:
Value to the Customer: By handling both the die-cutting and the heat-staking processes, Fairway Products provided a turnkey solution that streamlined the customer’s supply chain. This integration allowed the customer to receive ready-to-install RV screens, reducing assembly time and costs. The innovative use of refrigeration to maintain screen tension added a unique value, ensuring a superior product that enhances the end-user experience.
Fairway Products’ ability to deliver high-quality, scalable solutions with strict adherence to quality standards exemplifies their commitment to excellence in manufacturing. This project not only met but exceeded the customer’s expectations, solidifying Fairway Products as a trusted partner in the RV industry.