At the beginning of 2020, a Global 500 supplier of steering systems to the automotive industry was faced with a pressing problem. The worm wheels in their existing EPS (Electronic Power Steering) were making screeching noise during use, which was negatively affecting the quality of their product and the user experience. To solve this problem and ensure the safety and reliability of their products, they started to look for a new supplier of worm wheels for their EPS system, and NYLACAST AUTOMOTIVE , as a professional automotive solutions provider, was selected by the customer as their partner after rigorous testing and validation.

Precision tooth profile design

A Global 500 Tier 1 supplier of steering systems to the automotive industry needed a supplier who could provide a high quality, safe and reliable solution that met their exacting standards to solve a noise problem that was plaguing them.

Due to the very short development cycle of their EPS system, time was of the essence for them. They urgently needed a supplier who could respond quickly and provide timely samples and an accelerated serial production launch.

The unique Nylacast Automotive polymer casting process is characterized by its simultaneous polymerization, which is accomplished in a single step without the need for an additional process. The Nylacast polymers produced are higher in molecular weight and highly crystalline for improved material properties, strength and dimensional stability, which, combined with our high precision machining capabilities, gives the product higher NVH performance, not only solving noise problems, but also ensuring a longer service life and durability.

Proven, experienced and efficient casting process has successfully streamlined the development process. At the same time, our localized development and testing capabilities enable u to respond efficiently to demand and deliver products in a timely manner.

Nylacast Automotive has fully optimized production lines and equipment to meet large-scale customer orders. In 2023, we have an annual production capacity of 12 million worm wheels and growing. Through refined production management and optimized process flow, we can achieve “best-in-class” delivery cycles and ensure stable supply of products.

We are very satisfied with the rapid availability of samples and the mass production capability and product quality of Nylacast Automotive. Not only did they solve the noise problem we were facing, but they also successfully realized mass production within a matter of months. More importantly, the quality of their products is very consistent and meets our system requirements and expectations. Their professional team and advanced technology have provided us with excellent service and support. We appreciate their efficient work attitude, excellent results, and stable product quality. We will continue to work with Nylacast and recommend them to other partners.

Simon Harvey, CEO of Nylacast Automotive said：This was a monumental achievement. The team went from ground zero to mass production in a matter of 8 or so weeks. Our experienced, proven technology met the needs of the Customer, exceeded expectations and solved a serious field concern. Our passion to solve problems came to the fore, we scrambled and helped. I could not be prouder of what has been achieved here. The collaboration with the Customer was 1st class and demonstrates clearly what can be achieved when needs must.