When a critical mechanical failure halted production, SolCold needed a functional replacement part immediately. This case study shows how a PolyJet ToughONE™ gear, produced within 24 hours, enabled SolCold to restore full production and avoid weeks of downtime—demonstrating the value of additive manufacturing as a rapid-response manufacturing solution.
SolCold is an Israeli material science company founded in 2016 that develops solar-powered, passive cooling coatings. Its thin-film technology reflects solar radiation, converts excess heat into harmless light, and releases it through radiative cooling—reducing temperatures without electricity. SolCold operates a roll to roll manufacturing process to produce advanced cooling materials for industrial and commercial applications.
During the buildout of a new production line, SolCold experienced a mechanical failure caused by incorrect gear ratios in a critical subsystem. The issue prevented smooth handling of the material membrane, immediately stopping production.
Although a redesigned stainless steel gear had already been ordered, the three week lead time made it impossible to resume manufacturing while meeting customer delivery commitments. SolCold required a functional replacement gear within 24 hours to restart the line.
SolCold consulted several service bureaus to identify a rapid manufacturing option. Based on the mechanical requirements, the team recommended producing the gear using PolyJet ToughONE™.
Despite initial concerns about whether a polymer part could withstand the load of a moving mechanical system, SolCold provided the design and moved forward with the expedited print. The ToughONE™ gear was delivered within one day and installed immediately on the production line.
The PolyJet ToughONE™ gear performed reliably, allowing SolCold to resume full production while awaiting the metal component. The successful outcome changed the engineering team’s perception of polymer durability in mechanical applications.
As a result, ToughONE™ is now considered a practical rapid-response solution for future production line needs where fast turnaround is critical.
Key Results:
This case study highlights how PolyJet ToughONE™ can serve as more than a prototyping material. In time critical situations, it provides manufacturers with a way to:
