Fourstar Connections

Fourstar Connections Partners with XL Hybrids on Design for Manufacturing (DFM) Initiative

The Collaboration Resulted in Cost-Effective Connector Assembly Solution for Automotive Aftermarket Conversion Kit


Hudson, MA -- (ReleaseWire) -- 04/13/2016 --Fourstar Connections recently entered a collaborative partnership with XL Hybrids of Boston on a design for manufacturing (DFM) initiative. Fourstar Connections, a Hudson-based contract manufacturer to original equipment manufacturers (OEMs), helped build connecting assemblies for an automotive aftermarket hybrid-electric conversion kit. XL Hybrids uses energy storage solutions in its aftermarket hybrid-electric conversion kits for the automotive industry. This converts gasoline-dependent vehicles to hybrid gas/electric vehicles. XL Hybrids system improves the gas mileage for large fleets, and it also saves on vehicle brake maintenance costs because of its regenerative braking technology.

With its expanded in-house cable assembly capabilities, Fourstar Connections was able to reengineer the product design, acquire the specialized tooling to configure the connecting assemblies correctly, and complete the kits—at a lower cost and with significantly shorter lead time.

Phil Holman, President of Fourstar Connections, said, "Fourstar Connections is well-positioned to serve as an innovative supplier of DFM solutions to mission-critical connectivity challenges. Our initial engagement with XL Hybrids was to help them switch their cable source for both its HVAC and HVDC assemblies from a single vendor in Europe to multi-vendor source, that offered equal performance, lower cost, and supply chain flexibility to support its production spikes and order fulfillment. The engagement evolved from new product sourcing to providing DFM recommendations. We offered a full-turnkey solution, using the new cable source and in-house TE tooling to support the manufacturability of its HVDC assembly for new end-applications and configurations. XL Hybrids was able to simplify the product design and reduce the time to market for its hybrid-electric conversion kits. This aligns perfectly with our strength of being a solutions-driven partner to diversified industries."

For more information on Fourstar Connections and XL Hybrids partnership, download the design for manufacturing case study by clicking here.

About Fourstar Connections
Fourstar Connections, Inc. is an established company with an entrepreneurial spirit—having more than 25 years of experience, and offering a comprehensive portfolio of services and solutions to tackle a wide range of manufacturing needs. Fourstar Connections partners with leading companies to problem solve, innovate, and find better ways for new product introduction (NPI), and create design for manufacturing (DFM) initiatives. Its project management, manufacturing expertise, exceptional customer support, and advanced IT systems enable it to provide a comprehensive range of products and solutions—from cable assemblies to complex box build solutions—and quickly ramp up to meet target dates and volume requirements.

Custom built or customer specified, its flexible and scalable manufacturing services can be tailored to meet production needs—from high-mix, low-volume, to low-cost regions. Through Fourstar's strategic value-added reseller (VAR) relationships, it delivers functionality and value across the supply chain to improve efficiency, reduce costs, and enhance quality. Fourstar's 28,000-square-foot corporate headquarters and state-of-the-art manufacturing facility is located in Hudson, MA, with affiliate manufacturing facilities in Mexico and China. For more information on Fourstar Connections and its contract manufacturing capabilities, visit