{"id":26790,"date":"2025-12-18T21:36:40","date_gmt":"2025-12-18T21:36:40","guid":{"rendered":"https:\/\/www.leading-edge-strategy.com\/?p=26790"},"modified":"2026-07-31T09:47:37","modified_gmt":"2026-07-31T09:47:37","slug":"multidisciplinary-thermoplastic-product-development","status":"publish","type":"post","link":"https:\/\/www.leading-edge-strategy.com\/staging\/case-studies\/multidisciplinary-thermoplastic-product-development\/","title":{"rendered":"Multidisciplinary Thermoplastic Product Development"},"content":{"rendered":"

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Client Background<\/h2>\n

The client was part of a large US-based advanced manufacturing group specialising in the production of components in both metallic and composite technologies across the Aerospace and Defence, Automotive and Mobility Sectors. Within this group, our client is a specialist in the manufacture of thermoplastic composite components. Over several years, they have developed strong capabilities in lightweight composite structures, including wheels for off-road application. While these wheels performed well for their intended applications, they were never certified for use on commercial road-legal vehicles.<\/p>\n

The client approached the LES consulting team to explore whether their existing composite wheel manufacturing technology could be adapted for road legal applications. LES assembled a multidisciplinary team, comprising of experts in product design, engineering and simulation, composite manufacturing and industrialisation, testing, and automotive homologation, eventually delivering the design the engineering and prototypes for an Automotive light weight composite wheel, ready for production.<\/p>\n

Key Activities undertaken by LES <\/strong><\/h2>\n

Certification & Regulatory Analysis: <\/strong>Review of the certification landscape required to introduce a thermoplastic wheel into the automotive market. Regulatory pathways were mapped, identifying the key testing steps and defining the overall validation effort necessary for a road-ready product to establish the technical and regulatory scope of bringing a new wheel concept to market.<\/p>\n

Product Attribute Definition: <\/strong>Definition of the core performance attributes of a thermoplastic composite wheel. Key considerations included improving efficiency, enhancing performance and integrating sustainability principles – shaping both the engineering approach and the commercial positioning of the wheel.<\/p>\n

Global Electric Vehicle Market Analysis: <\/strong>Comprehensive assessment of the global EV market was carried out to identify the strongest commercial opportunities. Analysis covered projected vehicle production, segment trends and component compatibility to determine an optimal target vehicle and broader market applicability.<\/p>\n

Competitor & Pricing Landscape Assessment: <\/strong>Evaluation of existing market solutions to determine competitive positioning. Analysis included manufacturing approaches, pricing strategies and performance claims to help establish a realistic cost and price target ranges for the new component.<\/p>\n

Advanced Engineering & Design Development: <\/strong>A new component architecture was developed based on the defined performance requirements and optimised for TP composites manufacturing processes. The team carried out design work taking into account manufacturing constraints, materials and feature testing, structural assessment and virtual simulations to evaluate performance under relevant operating conditions. A full production concept was outlined, including key process steps and cost considerations for industrialising to scale the wheel production system.<\/p>\n

Prototype Demonstrator Development: <\/strong>A physical demonstrator of the concept was produced to support early evaluation and customer discussions. The prototype reflected the intended geometry and design direction, enabling stakeholders to visualise the concept without committing to full industrial tooling.<\/p>\n

Customer Engagement & Market Validation: <\/strong>Supported internal and external customer engagements, where the demonstrator wheel was presented to automotive manufacturers as part of a structured process managed by LES. Technical and commercial materials aided these discussions, allowing potential customers to assess the concept and its benefits. Feedback provided useful validation of the feasibility work completed.<\/p>\n

Summary<\/strong><\/h2>\n

This work spanned market analysis, design development, simulation, materials and processes evaluation, manufacturing technology down selection and TRL tracking, prototyping and \u201cgo to market campaigning\u201d, all delivered through a coordinated and integrated approach. LES can combine strategic insight with technical expertise to guide a new concept from early-stage exploration through to tangible demonstrator. The project stands as a clear example of a turnkey solution with effective cross-functional collaboration, enabling a clear definition of a product strategy, associated business case validation and executive advisory on go to market strategy.[\/vc_column_text][vc_empty_space height=”40px”][vc_column_text]SERVICE CATEGORIES:<\/strong><\/span>[\/vc_column_text][vc_raw_html]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[\/vc_raw_html][\/vc_column][vc_column css=”.vc_custom_1766093997610{padding-top: 200px !important;padding-bottom: 200px !important;background-image: url(https:\/\/www.leading-edge-strategy.com\/staging\/wp-content\/uploads\/2022\/12\/Wheel2.png?id=26788) !important;background-position: center !important;background-repeat: no-repeat !important;background-size: cover !important;}” offset=”vc_hidden-lg”][\/vc_column][vc_column offset=”vc_hidden-lg” css=”.vc_custom_1611247142375{padding-top: 60px !important;padding-right: 20px !important;padding-bottom: 30px !important;padding-left: 20px !important;}”]

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<\/div><\/div>[vc_empty_space height=”10px”][vc_column_text]Background<\/strong><\/p>\n

The client is positioned at the heart of domestic advanced manufacturing and innovation integration across industry, academia, and the public sector.<\/p>\n

As part of a strategy refresh, the client wanted to ensure their technology focus was aligned to the country\u2019s net-zero goals consolidating their ability to support SMEs operating directly in, or in the supply chain of, key consumptive and polluting sectors.<\/p>\n

The project was positioned as an opportunity to re-evaluate the client\u2019s strategy and external engagement to ensure their in-house state-of-art capabilities in sustainable advanced manufacturing technologies could be targeted to provide optimal benefit across the domestic manufacturing market.<\/p>\n

Scope & Deliverables<\/strong><\/p>\n