Real results for real companies.
See how we've helped businesses across industries build better parts, faster — from DFM through tooling and production.
Industry
Ride-share fleet operations
Volume
~300 bumpers / year
Process
Vacuum thermoforming + CNC (4 mm ABS)
Challenge
An Uber fleet operator asked us to make a replacement front bumper — but split into three modular sections for easier field repair, and economically viable at only ~300 units per year. Parts like this are usually injection molded at hundreds of thousands or millions of units to break even.
Solution
We redesigned the bumper from first principles: modular geometry, a low-volume process stack (vacuum thermoforming plus CNC milling from 4 mm ABS sheet), DFM tuned to that process and material, and logistics that work at fleet scale — not factory scale.
Result
The prototype fit on the first try. With mold cost amortized over 12 months, unit economics landed around 30% gross margin in year one and roughly 50% after — proof that creative design-for-manufacturing can make "impossible" low-volume fleet parts real.
Project Photos
Industry
Solar Energy Startup
Timeline
1 month
Challenge
Raya needed samples and production parts ASAP as they had to deliver to their first customers. Timeline was very tight, one month, and the shells that housed the battery and solar powers were very large and complex, which could make molds impossibly expensive.
Solution
Through full support from DFM to mold production, and a logistics setup, Vasar helped Raya successfully deliver their pilot programs and have tooling and production set up for growth needs.
Result
DFM to production in 30 days. Successful pilots delivered to their customers on time. Tooling and production capacity established for future growth.
Industry
Defense
Timeline
1 month
Challenge
As part of efforts for upgrading their surveillance fleets, the Mexican Defense Secretariat needed reinforced gears for a rotating lamp, since the original product had a very weak plastic gear that needed frequent replacements.
Solution
We had to quickly reverse engineer the gear and proposed both nylon and brass alternatives, making the gear much more suited for the wear and tear of intense operations. We also ended up saving them 65% in maintenance expenditures for this lamp.
Project Photo
Industry
Trucking
Timeline
Custom
Challenge
Develop a fuse lid cap spare part for repairing Freightliner Cascadia trucks. We had to develop a spare part from scratch.
Solution
An injection molded spare part that reduces part expenditure by 70% and installation time by +90%.
Project Photos
