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Art-to-Part-Engineering
...Automotive-Components
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Customer
A premium-segment Japanese automotive manufacturer.
Localization of various engine components was required.
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Scope
Design and manufacture of 2 critical injection-molded plastic components for the engine radiator.
Engineering tasks included
3D-modeling, mold tool design, mold flow simulation, mold manufacture and volume component production.
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Components
Upper and lower radiator tanks composed of 30% glass-filled composite nylon material
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Timeframe
90 days from start to completion.
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Engineering Sequence:
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Design: 2D Component Drawings
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Design: 3D-Component
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Analysis: 3D-Mold filling and cooling
...validation of flow injection points
...validation of cooling characteristics |
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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 ...material choice for abrasive glass-filled polymers ...cross-functional team reviews |
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DFM: 3D-Mold one-half Assembly
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DFM: 3D-Mold other-half Assembly
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DFM: Complete Mold Assembly
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Design Validation: Actual Mold
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Design Validation: Actual Component
...first-trial success
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