Friction solution for slip clutch

When a Toronto-based company, with several of the world’s most well-known passenger car brands on its customer list, was preparing to start series production, a critical issue emerged. The friction material in their slip clutch did not meet requirements at production scale – despite prototypes having previously passed both short- and long-term field tests.

Friction Solution for Slip Clutch

When a Toronto-based company, with several of the world’s most well-known passenger car brands on its customer list, was preparing to start series production, a critical issue emerged. The friction material in their slip clutch did not meet requirements at production scale – despite prototypes having previously passed both short- and long-term field tests.

The existing supplier had delivered functional prototypes but lacked the capability to ensure consistent quality in mass production. The situation was business-critical. Without a working solution, the entire product launch was at risk of being halted.

Rapid Transition Under Time Pressure
In the search for a new partner, Rydahls was contacted. Our initial assessment was clear: with the right material selection and design adaptation, there were strong prospects of resolving the challenge. Shortly thereafter, the customer’s product manager traveled to Sweden – carrying metal carriers for testing in hand luggage. The assignment was concrete: a finished prototype to bring back home before the end of the week.

Material Selection Based on Calculations and Application Requirements
The requirements for the friction solution were extensive. The material needed to be:

• Punchable

• Thin and formable

• Bendable and flexible

• Dimensioned for specified speed and temperature loads

Our engineers carried out detailed calculations and developed a design proposal based on the friction material RY277. The material was processed, bonded, and assembled according to specification – and delivered within the agreed timeframe.

Verified Performance and Long-Term Partnership
Subsequent short-term testing confirmed functionality and performance. Long-term tests also met all specified requirements, enabling the planned start of series production.

The collaboration has since evolved further. Through process optimization, we have, among other improvements, replaced punching with waterjet cutting of the friction material. The result is reduced material waste, improved resource efficiency, and stronger business value for the customer.

This case illustrates how the right material expertise, technical analysis, and rapid delivery capability can be decisive when production-critical challenges arise.

Customer case