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Art-to-Part-Engineering
...Automotive-Components
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Customer
A luxury-class automotive manufacturing group
from Japan. Rapid and highest-quality
localization was required to maintain a targeted selling-price
and launch the product within a tight time schedule
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Scope
Design and manufacture of selected injection-molded plastic components.
The total job involved reverse engineering through 3D-scanning, 3D-modeling,
mold tool design, mold flow simulation, mold manufacture and volume component
production.
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Components
A total of 9,including battery tray, air-guide panel, splash-shield,
under-cover panel, water-guide
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Timeframe
120 days from start to completion.
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Cost Savings
The customer achieved a saving of 75%, compared to the cost of
sourcing 3D designs and tools from overseas and with no compromise on
product quality
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Engineering Sequence:
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Design: Reverse Engineering ( 3D scanning, surface reconstruction)
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Design: Completed 3D-Component
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DFM: 3D-Mold Assembly
Manufacturability considerations for the assembly, injection, cooling and ejection cycles:
...optimum side-core count ...optimum insert placements ...optimum location of injection points ...choice of hot and cold runners ...optimized cooling methods ...suitable ejection mechanisms ...tool life-cycle considerations ...cross-functional team reviews |
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DFM: 3D-Mold Assembly (core and cavity sub-assemblies)
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Design Validation: Actual Mold
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Design Validation: Actual Component
...first-trial success
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