The Process
Tube Fabrication
The process of taking raw tubing and performing key operations such as cutting, bending, milling and forming to meet specific part specifications is known as tube fabrication. Polaris’ in-house tube fabrication reduces supply chain lead time and improves product quality. Throughout this process, CAD data is used to precisely locate holes or other cutout designs, identify bend locations and to verify bends meet specifications. Use of CAD allows us to maintain tight tolerances on complex fabrications and verify dimensional accuracy.
Welding
In Roseau, Minn., Polaris has 77,000 square feet of state-of-the-art welding space, with 25 robotic welding systems including 46 arms, plus more than 80 manual welding stations. All weldments are produced on fixtures to assure dimensional accuracy at completion and robotic welding is used wherever practical. Many items are welded in-house including vehicle chassis, ROPS, steering and suspension components. Welding internally greatly reduces component lead times while increasing production quality and efficiency.
Quality Assurance
Quality inspection is a key area where components and weldments are measured to a print specification and weld quality is rigorously tested using macroetching and metallurgy inspection. Polaris delivers world-class military vehicles by using industry-leading techniques and approaches to quality assurance – DC torque tools, 3D scanning, AI detection systems. The Polaris quality process drives a purposeful approach to understanding customer needs and ensures they are translated through design, validation and manufacturing to provide products that exceed expectations.
Wash, E-Coat & Paint
A multi-step wash process removes contaminants and oils to maximize paint adhesion and improve paint performance. Electrophoretic Painting (E-Coat) is used on the chassis, ROPS and other metal components to provide superior corrosion resistance not only to the outer surfaces, but the inner surfaces as well. Once cured, a topcoat of powder paint is applied to metal parts for additional durability and UV protection. Polaris also has a robust liquid paint capability, which is used primarily on plastic parts. Our washing, e-coating and painting systems are all environmentally friendly, meeting and exceeding EPA standards through Polaris’ own internal waste treatment center.
Sub-Assembly
Polaris builds many sub-assemblies in-house, including brakes, shocks, control arms, and cooling systems. Quality is controlled by detailed Visual Work Instructions (VWIs) at each workstation. Component bar codes are scanned prior to assembly, which results in a robust quality record traceable by VIN. Having in-house sub-assembly capabilities allows Polaris to reduce supplier lead times and ensures the highest levels of quality control.
Tube Fabrication
The process of taking raw tubing and performing key operations such as cutting, bending, milling and forming to meet specific part specifications is known as tube fabrication. Polaris’ in-house tube fabrication reduces supply chain lead time and improves product quality. Throughout this process, CAD data is used to precisely locate holes or other cutout designs, identify bend locations and to verify bends meet specifications. Use of CAD allows us to maintain tight tolerances on complex fabrications and verify dimensional accuracy.
Welding
In Roseau, Minn., Polaris has 77,000 square feet of state-of-the-art welding space, with 25 robotic welding systems including 46 arms, plus more than 80 manual welding stations. All weldments are produced on fixtures to assure dimensional accuracy at completion and robotic welding is used wherever practical. Many items are welded in-house including vehicle chassis, ROPS, steering and suspension components. Welding internally greatly reduces component lead times while increasing production quality and efficiency.
Quality Assurance
Quality inspection is a key area where components and weldments are measured to a print specification and weld quality is rigorously tested using macroetching and metallurgy inspection. Polaris delivers world-class military vehicles by using industry-leading techniques and approaches to quality assurance – DC torque tools, 3D scanning, AI detection systems. The Polaris quality process drives a purposeful approach to understanding customer needs and ensures they are translated through design, validation and manufacturing to provide products that exceed expectations.
Wash, E-Coat & Paint
A multi-step wash process removes contaminants and oils to maximize paint adhesion and improve paint performance. Electrophoretic Painting (E-Coat) is used on the chassis, ROPS and other metal components to provide superior corrosion resistance not only to the outer surfaces, but the inner surfaces as well. Once cured, a topcoat of powder paint is applied to metal parts for additional durability and UV protection. Polaris also has a robust liquid paint capability, which is used primarily on plastic parts. Our washing, e-coating and painting systems are all environmentally friendly, meeting and exceeding EPA standards through Polaris’ own internal waste treatment center.
Sub-Assembly
Polaris builds many sub-assemblies in-house, including brakes, shocks, control arms, and cooling systems. Quality is controlled by detailed Visual Work Instructions (VWIs) at each workstation. Component bar codes are scanned prior to assembly, which results in a robust quality record traceable by VIN. Having in-house sub-assembly capabilities allows Polaris to reduce supplier lead times and ensures the highest levels of quality control.
The Assembly Line
Final vehicle assembly is performed on an advanced manufacturing line operated by highly experienced personnel. Each vehicle frame is mounted onto a moving carrier that travels to designated workstations, where assembly and quality inspection processes are completed based on VIN. Polaris manufacturing lines use detailed visual work instructions (VWIs), DC Torque tools, 3D scanners, automated fluid fill, electronic end of line “rolling road” and numerous other tools that provide our military and government customers with a detailed record of each vehicle manufactured. Quality inspections are also recorded by VIN and maintained in the manufacturing record for each vehicle produced. Final assembly for the new MRZR Alpha is completed on Polaris’ new, dedicated defense manufacturing line in Roseau, Minn.
The Finished Product
