CASE STUDY: LED HOUSING
In May 2008, the engineering staff of Schneider Electric asked Token Aluminum to develop a high-conductivity aluminum alloy, which did not exist at the time. The core requirement was that conductivity should be 56.5% to 58% IACS while achieving a tensile strength of 172 to 220 MPa.
TOKEN PULLED TOGETHER A TEAM OF SPECIALISTS AND ACADEMICS TO CONDUCT R&D OVER THE NEXT 6 MONTHS, INCLUDING:
1 Screening the beneficial alloy elements for conductivity to reduce the resistance rate of aluminum
2 Conducting an exhaustive design of experiments under controlled conditions and testing the resistivity and mechanical properties
3 Testing to confirm a rare metal element, which was found to be most effective in reducing resistivity
4 Development to limit the reasonable collocation of silicon and iron [M2] content
5 Developing purification technology of liquid[M3] aluminum
6 Determination of the optimal effective temperature of heat treatment
Ultimately, Token succeeded in achieving and exceeding the requirements of France Schneider. In 2009, Token was officially recognized in the global supplier list of France Schneider, and received the Global Best Supplier award from Schneider.
CASE STUDY: SOLAR
Our solar mounting system customer needed to quickly launch a new product line. This system included 6 main components consisting of 32 unique parts, primarily fabricated aluminum extrusions and custom stainless hardware. These components were small, complex and intricate, with tolerances much tighter than Aluminum Association standards. The primary component comprised an assembly of 3 custom extrusions and 8 custom stainless hardware parts that required anodizing, CNC machining, punching, pressing, gluing, subassembly, assembly, and custom packaging.
Token brought in 30 new employees to handle the production surge and set up custom fabrication and assembly lines. We passed all first article inspections quickly and began production within 8 weeks of the order. We kept up with demand by producing 1 container per week in the first two months, then increasing to 2 containers per week. The customer was extremely satisfied with our quick turnaround time and ability to produce a high volume of quality products.