What’s possible when material knowledge, application understanding, and process insight come together.
The Challenge
R&D Europe was supporting a customer experiencing premature wear in critical areas of complex ISBM tooling. Tools were failing well before their expected service life, leading to:
• Unplanned downtime
• Reduced productivity
• Increased maintenance and replacement costs
The challenge was to restore reliability and performance in a demanding, high-wear application.
The Approach
Rather than treating the issue as a simple tooling replacement, BÖHLERworked collaboratively with R&D Europe to understand the root cause of the wear mechanism.
By analysing the application and operating conditions, abrasive wear driven by the aggressive nature of the plastic pre-material was identified as the dominant factor.
This insight shaped the direction of the solution.
The Solution
Based on the findings, BÖHLER recommended M390 MICROCLEAN, a powder metallurgy plastic mould steel offering:
• Exceptional hardness
• Outstanding wear resistance
• Strong corrosion protection
Trial material was supplied, enabling R&D Europe to manufacture and validate prototype tooling through extensive in-house testing before moving into full production.
The Results
The outcome was a step change in performance.
• Tool life increased by over 400%
• One tool component now delivers the output previously requiring four replacements
• Tool maintenance and downtime were significantly reduced
• Machine uptime and production continuity improved
The solution delivered both immediate performance gains and long-term operational benefits.
More than a material supplier, BÖHLER works collaboratively with customers to share expertise, challenge assumptions, and deliver improvements that extend far beyond the tooling itself.
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