Views: 0 Author: Danny Luo Publish Time: 2024-12-05 Origin: Site
Our Services: DFM Report, Injection Mold Design, Plastic Mold Manufacturing , Plastic Injection Molding Mold Steel: S136 Mold Cavity: 1*2 Plastic Material: PBT+GF30 Surface Treatment: Texture (VDI 27) |
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In August 2023, Frico, a German client specializing in automotive radar systems, approached Alpine Mold with a highly time-sensitive request for radar casings for automobiles. The client’s goal was to complete a large-scale production of high-performance radar casings using PBT+GF30% material, meeting the automotive industry’s stringent fire resistance specifications, within one month delivery time.
The project required not only rapid delivery but also precision in mold design and surface treatment to ensure optimal product performance and visual appeal. Given the complexity and urgency, Alpine Mold was tasked with creating a custom injection mold solution that would meet all of the client’s functional and aesthetic requirements.
Upon receiving the initial inquiry, we conducted in-depth discussions with Frico to understand their precise requirements. This included:
Material Selection: PBT+GF30 (Polybutylene Terephthalate with 30% Glass Fiber) for its excellent thermal and chemical resistance, as well as its suitability for the automotive sector.
Surface Treatment: Texture (VDI 27) to achieve the required visual finish.
Mold Design: Mold cavity configuration of 1*2 to produce the necessary radar casing components efficiently.
Within 24 hours of the inquiry, we provided Frico with a detailed quotation, the material data sheet, and initial mold design data, demonstrating our commitment to rapid and thorough service.
2. DFM Report and Initial Mold Design (Week 1– August 2023):
After receiving confirmation from the client, Alpine Mold’s project manager promptly communicated the mold requirements and technical drawings to the engineering team. We began the DFM (Design for Manufacturing) report to identify any potential manufacturing challenges.
Potential Issues: During the DFM review, we identified potential concerns such as excessive thickness of product ribs and self-tapping screw holes that could lead to shrinkage marks on the final product.
Solution: After thorough discussion with Frico, we proceeded with the mold design and and created a prototypeto verify the design’s feasibility.
3. Mold Production and Testing (Week 2 to 4– August 2023):
After Frico confirmed the 3D Mold Assembly drawing, we maintained regular communication with Frico, providing weekly progress updates, mold images, and adjustments as needed. Despite the urgency of the project, we carefully monitored the process to ensure the mold met all technical specifications.
Mold Trial & Challenges: In September, during the mold trial process, we encountered minor defects such as slight shrinkage marks, ejector pin marks, and product warping. While we adjusted the mold parameters to mitigate these issues, they persisted in the T0 sample.
Customer Feedback: Frico accepted the sample temporarily but requested a thicker texturing (VDI 27) to minimize surface defects.
4. Optimization and Final Testing (Week 4– August 2023):
By the fourth week of August , after a thorough meeting with Frico, we all agreed on the following improvements:
Gate Relocation: Changing the gate from side-gating to sub-gating for better material flow and to prevent cosmetic defects.
Material Change: Swapping the PBT+30%GF material for a more optimal version for radar casing production.
Revised Testing: The third round of mold testing incorporated these changes, resulting in significant improvements in product quality.
Frico was highly satisfied with the new results, approving the final mold design and production process.
5. Packaging and Final Delivery ((Week 5, September 2023):
As the project neared completion, we encountered a minor issue regarding the packaging strength, which led to higher-than-expected return rates. To resolve this, we proposed enhancing the vacuum-formed packaging for improved durability. Frico agreed to the additional cost, ensuring the product was adequately protected during shipping.
Superior Product Quality: The final radar casings met Frico's fire resistance and dimensional accuracy requirements, ensuring they performed reliably in automotive applications.
On-Time Delivery: Despite the project’s tight timeline, Alpine Mold successfully delivered the molds and samples within the agreed one-month deadline, demonstrating our commitment to efficient, high-quality production.
High Customer Satisfaction: By maintaining continuous communication and addressing challenges proactively, we earned Frico’s trust and approval, ensuring the radar casings met their rigorous expectations for the automotive industry.
Throughout the project, our team worked closely with Frico, mold engineers, injection molding engineers, and project managers to resolve any issues and optimize product quality. In the end, we delivered high-performance radar casings that met all customer requirements, strengthening our relationship and ensuring long-term satisfaction.
Looking for High-Quality Custom Plastic Injection Molds for Automotive Parts? Contact us today for a tailored solution. We specialize in precise automotive mold manufacturing and automotive injection molding services, designed to meet your exact specifications. Get a detailed quotation and see how we can support your next automotive project with reliable, high-performance solutions!
