Precision injection mold tooling for automotive temperature sensor housing

Project Overview

In today’s automotive industry, precision injection mold tooling plays a crucial role in the manufacturing process of various components. This is especially true for complex parts such as mold tooling for automotive temperature sensor housing, which require high precision and durability to withstand the harsh conditions of an electric vehicle.

The client for this project was a leading supplier of automotive parts who required a mold to produce a new component for an electric vehicle model. The part was a temperature sensor housing with complex geometries and tight tolerances, which needed to withstand high temperatures and thermal cycling.

The challenges faced during the design and manufacturing of the mold were significant, and required a high level of expertise and attention to detail. The mold needed to be designed with an optimized cooling system to achieve a uniform temperature distribution and prevent warpage. Additionally, the manufacturing process required high precision in machining due to the complex geometry of the mold.

Designing Process

The first step in the project was to analyze the part design and identify all critical features, dimensions, and tolerances. This was necessary to ensure that the mold would produce a high-quality component that met the client’s specifications. One of the challenges faced during the design process was to create a mold with an optimized cooling system to achieve uniform temperature distribution and prevent warpage.

To overcome this challenge, advanced simulation software was used to simulate the injection molding process and optimize the mold design. This software allowed us to predict and analyze the behavior of the plastic material during the molding process. As a result, the design was optimized to ensure that the part would be produced with the required precision and efficiency.

After several iterations, our engineer recommended a two-cavity hot runner mold design with conformal cooling channels. This design provided the required precision and efficiency by ensuring that the temperature was uniform throughout the mold, thus preventing warpage. The hot runner system allowed for precise control of the plastic flow, which resulted in a high-quality component. The conformal cooling channels were designed to follow the contours of the part, providing optimal cooling and reducing cycle time.

Manufacturing Process

Once the mold design was finalized, we began the manufacturing process. The mold was fabricated using high-quality materials, including hardened steel and precise cooling channels. The use of high-quality materials was crucial to ensure the durability and longevity of the mold.

One of the main challenges encountered during the manufacturing process was the need for high precision in machining due to the complex geometry of the mold. To achieve the required level of precision mold tooling, we utilized advanced CNC machining equipment, including 5-axis milling machines and EDM. These machines allowed for high accuracy and consistency in every aspect of the mold.

Throughout the manufacturing process, rigorous quality control measures were conducted to ensure that every component of the mold met the client’s specifications. This included conducting regular inspections and tests to ensure that the mold was manufactured to the required tolerances and dimensions. Any deviations from the specifications were identified and corrected immediately.

Mold Validation and Testing

After the mold was manufactured, extensive validation and testing were conducted to verify its performance and reliability. Our engineer used advanced German Zeiss CONTURA CMM and optical inspection systems to check dimensional accuracy, surface finish, and other critical parameters. These systems ensured that the mold met the required tolerances and dimensions.

Injection molding trials were also conducted to optimize the process parameters and ensure consistent quality. The injection molding process was simulated using advanced software to identify and eliminate any defects in the molded parts. This process ensured that the final component was of high quality and met the client’s specifications.

Various tests were conducted to validate the performance and durability of the molded automotive parts, including thermal cycling and resistance to chemical corrosion. The molded parts were subjected to rigorous testing to ensure that they could withstand the harsh conditions of an electric vehicle. These tests were crucial in ensuring the reliability and longevity of the molded parts.

trial injected automotive temperature sensor housing

Results

The final injection mold exceeded the client’s expectations in terms of speed, precision, and durability. The use of a two-cavity hot runner mold design with conformal cooling channels allowed for faster cycle times and reduced the amount of waste produced during the injection molding process. Additionally, the advanced simulation software and the use of high-quality materials and CNC machining equipment ensured that the mold was precise, consistent, and durable.

Furthermore, the molded automotive parts met all required specifications and passed rigorous quality tests. The parts were able to withstand the harsh conditions of an electric vehicle, including high temperatures and thermal cycling. The use of conformal cooling channels ensured uniform temperature distribution throughout the part, preventing warpage and ensuring dimensional stability. The parts also demonstrated resistance to chemical corrosion, which is critical in the automotive industry.

Overall, the results of the project demonstrated the ability of M2 Prototype to deliver high-quality solutions that meet the customer’s needs. The final injection mold and molded parts exceeded the client’s expectations in terms of speed, precision, and durability, and demonstrated the importance of precision injection mold tooling in the automotive industry.

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