Pre & Post Production
Precision doesn’t begin when production starts—and it doesn’t end when the tooling is delivered. Laval’s solutions provide the engineering, optimization, and technical support needed to move seamlessly from development into production and beyond. We work proactively at every stage to identify opportunities, eliminate inefficiencies, and ensure every component of the process is engineered for performance.
From early design validation and process optimization to tooling refinement, troubleshooting, maintenance, and continuous improvement, we keep production moving forward. By connecting the stages before, during, and after manufacturing, we create a more intelligent, resilient, and future-ready production process—built not just for today’s requirements, but for what comes next.
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Case Study: WAYMO Roof Pod
Our strength lies in mastering the full composite lifecycle—tooling, automation, and production working as one seamless system. This allows us to move quickly without sacrificing precision, adapt designs without slowing momentum, and deliver production-ready solutions that meet the demands of next-generation BEV platforms.
Pre-Production Molding and Part Validation
Initial SMC and TPO parts were molded and evaluated for cure, dimensional stability, surface quality, and suitability for routing, bonding, and final assembly.
Pre-Production Fixture and Bonding Development
Early trials identified inconsistent part seating, hole locations, trimming, glue placement, and routing-dust accumulation. Bonding controls were established for flaming, Dyne testing above 50 dynes/cm², cleaning, surface activation, and robotic glue application
Pre-Production Equipment and Operator Readiness
Routing, flaming, robotic tooling, fixture locking, and safety systems were validated. Fixture height, part supports, counterweights, lighting, and workstation kitting were improved to safely manage up to 139 components and support consistent operator performance.
Post-Production Routing Repeatability
MMC pre-locators, four Z-datums, shim-adjustable net pads, and dust-clearance holes were added. These improvements achieved hole-location repeatability within ±0.2 mm and reduced routing defects from approximately 8% to less than 1%.
Post-Production Final Assembly and Quality Control
Locator pins maintained SMC-to-TPO placement within ±0.5 mm during bonding. Proximity sensors, Andon lights, glue timers, buzzers, torque checks, and component verification supported the final installation of fasteners, lower covers, radar, cameras, and electrical components.
Post-Production Results and Standardization
Fixture stability, ergonomics, lighting, mobility, and kitting improvements reduced cycle time by approximately 20%, lowered missed pal nuts from 4% to below 0.2%, and significantly reduced scrap and rework. The validated methods were incorporated into standard procedures for future SMC/TPO production programs.
Get In Touch
Let us know how we can help you start your project.
(519) 737-1323
(519) 737-1747
office@lavaltool.net
4965 Concession Road 8, Tecumseh, ON N0R1K0
