NORCO partners with WADAL Plastics to develop corner key for windows

WADAL's concept-to-production approach is best exemplified in a project with NORCO, a window and patio door manufacturer and wholesale distributor to construction companies. NORCO had a business concern to resolve, and through its partnership with WADAL Plastics, a cost-efficient solution was developed.

The Business Issue
In the early 1990's, it became apparent that homes built with synthetic stucco were plagued with moisture retention problems. The stucco-like finish was waterproof, but this factor made it extremely difficult to remove moisture that inadvertently leaked inside the wall cavities. Homeowners and inspectors began to uncover rotting walls and interior staining. Consumer complaints increased, and litigation against the material manufacturers became a common course of action.

Sources of water entry were found to include gaps between window frames and walls. Although improper installation or weak structural support could cause the gap formation, NORCO believed that improvements to its overall window design could alleviate some of the issues.

The Concept
NORCO focused its efforts on casement and double-hung windows. The concept was a plastic corner key, which would be added to window extrusions during the production phase. The corner key would not only maintain the structural integrity of the window while in transit to suppliers, it would also seal the mitered joint after installation.

Partnering with WADAL Plastics
John Gibbons, a senior NORCO engineer, spearheaded the project internally. One of his primary responsibilities was to evaluate and choose an injection-molding partner. John became aware that WADAL Plastics produced similar parts for other window manufacturers, so he approached them with the NORCO concept. After touring the WADAL manufacturing facility and interacting with the engineering staff, both companies knew that they found a solution.

The Process
To determine the proper sizing and cavity requirements, NORCO shipped multiple window extrusions to WADAL. WADAL's engineers then designed two corner keys, one for the casement window and one for the double-hung version. During the review process, three-dimensional drawings were sent to NORCO electronically and on-going discussions took place via the phone. WADAL also provided recommendations for materials based on durability and cost.

The Test
Within a week of preliminary design approval, WADAL produced a fast-tracked SLA model and sent it to NORCO for analysis. A silicone mold and thirty cast-urethane parts were also produced and approved two weeks later. NORCO followed this activity with in-house tests to confirm 'fit and function' with the extrusions, sealant flow, secondary operation needs, and compatibility with existing assembly equipment. Though the part was complicated in nature, the review and testing phases proceeded smoothly. Confident in the results, NORCO directed WADAL Plastics to build the final multiple cavity tool.

The Outcome
Using state-of-the-art equipment, WADAL Plastics is in a full production mode of the approved corner keys. Parts are currently supplied to NORCO's facilities in Ringtown, Pennsylvania and Hawkins, Wisconsin.

Benefits to NORCO
Based on feedback from John Gibbons, NORCO is extremely satisfied with the partnership formed with WADAL Plastics. Benefits to outsourcing the project include WADAL's comprehensive production capabilities, lower tooling costs, and a one-stop shopping environment for NORCO.

"Our corner keys were produced with only one modification to each prototype. This is a solid testament of WADAL's dedication to streamline the development cycle, and ensure that enough time is spent on the front end to avoid false starts along the way."

For more details regarding WADAL Plastics' ability to transform ideas into cost efficient parts, please contact us at 715-748-2227 or send an email to wadal@wadalplastics.com.