Supported one of the top Tier-1 Suppliers’ India R&D team in prototype development of a multi-piece plastic over-molding on a steel wire that was shipped to their Poland plant
Plastic Carrier Functional Prototype
Client: CONFIDENTIAL
Industry: Automotive
Region: India
Process: Production Tooling, Injection Molding
Requirement
- Client is a long-term partner for prototyping projects
- Needed a plastic carrier prototype in 30% glass filled PP, over-molded on a steel wire
- Key challenge to ensure position of the steel wire is not displaced during the molding process
- Four different parts to be molded together using a single tool
- Component to be shipped to Poland for testing
Project Details
Part Details
Part Name: Plastic Carrier
Application: Functional prototyping
Quantity: 400
Manufacturing Details
Processes: Prototype Tooling, Injection Molding
Material: 30% Glass Filled Polypropylene
Delivery Details
- Tooling developed within 4 weeks and production completed in 6 weeks from project kick-off
- Fitment validation on checking fixture
Approach
- DFM, tooling feasibility study and Moldflow analysis conducted by Design team
- Simultaneous planning for the tool and molding process to mold all four components together
- Mold made using a 3 drop Hot Runner Manifold
- Wire fixing mechanism in mold developed to ensure no deviation during over- molding process
- CMM and fixtures developed and produced for part testing
- Packaging 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
