Built functional prototypes of a twin degassing tank in PP by developing and assembling three injection molded parts using the hot plate welding process
Twin Degassing Tank Functional Prototype
Client: CONFIDENTIAL
Industry: Automotive
Region: India / Europe
Process: Production Tooling, Injection Molding
Requirement
- Indian subsidiary of a France-based Tier-1 Supplier was developing a new twin degassing tank for an Indian Auto OEM
- Required an assembled functional prototype in Polypropylene within a development time frame of 4 weeks
- Design had three parts that needed to be assembled using hot plate welding
- Parts to be used for prototype cars in North America
Project Details
Part Details
Part Name: Twin Degassing Tank
Application: Functional Prototyping
Quantity: 350
Manufacturing Details
Processes: Prototype Tooling, Injection Molding, Hot Plate Welding
Material: Polypropylene
Delivery Details
- Tooling developed within 4 weeks
- Hot plate welding process optimized for assembly
Approach
- Conducted DFM and Moldflow analysis for the three parts
- Prototype tool developed
- Specific grade of PP imported as per requirement
- Post production refinements with Tristone to optimize the hot plate welding process, developed fixtures and joined parts for final assembly
- Checking Fixtures and Gauges designed and manufactured to measure tight tolerances required
- Final quality inspection
Impact
- Developed and delivered prototype tooling within 4 weeks, one-third the time required for production tooling (12 weeks)
- Tight tolerances achieved for dimensional accuracy
- Managed supply chain efficiently to adhere to development timelines
