Offered complete prototype product development from concept to part supply for a German OEM for a new headlight design
Head Lamp Functional Prototype
Client: CONFIDENTIAL
Industry: Automotive
Region: India / Germany
Process: Production Tooling, Injection Molding
Requirement
- Client required a development partner to provide end-to-end support for prototype assemblies in a series of new lighting developments
- Scope of work included product design to adapt to a proto lamp requirement, plastic part production, procurement of standard parts from Germany, assembly, and testing
- Required to offer design improvements and check the package in the vehicle environment and arrange design reviews with customer engineering
- Functional and crash prototypes to be finally shipped to Germany for the proto car build
Project Details
Part Details
Part Name: Head and Tail Lamp, incl. Crash Lamp
Application: Functional Prototype
Quantity: ~250 lamps per project
Manufacturing Details
Processes: Prototype Tooling (Aluminum and Steel), Injection Moulding, Assembly, Testing
Material: Polycarbonate, 30% Glass Filled Polypropylene
Delivery Details
- 10 unique tools completed within 8 weeks and part supply started within 10 weeks from project kick-off
- 2,773 functional and 1,640 crash prototypes till date over 10+ Car Lines
Approach
- Complete design for component and mold, along with analysis
- Tooling and injection molding for housing, lens, other small parts
- Selected components procured based on client’s specification
- Sheet metal components & dead weight for crash lamp designed and procured
- Complete lamp assembled in -house and tested to requirements including electronics testing
- Dedicated closed entry assembly area with anti static ESD flooring
- Fixture developed for testing at ARAI
- Assembly packaged for export
Impact
- Complex molding of all four components with over-molding on the given wire achieved seamlessly
- DFM and tooling feasibility study appreciated by the client
- Continued long term relationship through successful delivery of complex projects
