Case Studies: Consumer Products

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Sports equipment manufacturer

A startup company was developing state-of-the-art anti-concussion helmets and had a firm product launch date. The product was not meeting test requirements, so the customer made numerous last-minute design changes, requiring modifications to the mold tooling.

Due to the critical product launch date, samples would need to be molded, tested, and production molded under an extremely aggressive schedule.

Further, in a last-minute request, the customer asked for the helmet shells to be produced in multiple colors, requiring unplanned color matching and resin formulation.

Seaway modified the tools and molded the parts for testing; the helmet parts passed the rigorous testing; Seaway performed color-match and resin formulation on an ultra-rush basis then production-molded the innovative new helmets in 14 different colors. The helmets were then assembled under a 24/7 schedule, including weekends.

The product launch date was made and the customer gave Seaway Plastics high accolades.

“We could not have done this without you. We made our deadline and our team would like to say thank you for pushing with us. As a small startup, every deadline that we hit is critical to our business and the success of our company. I know we tend to change directions every hour, so we appreciate your team adapting with us. I’d also like to say your team handled our stress with grace and professionalism, which makes our company happy that we have Seaway as our contract manufacturer. We are not done yet, but for now we are happy that we hit this milestone. We appreciate the Seaway team and all of its effort!”

- Startup sports equipment manufacturer

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