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Injection Molded Electrical Enclosure

Application: Electrical Enclosure (Automotive)
Size: 240X190X90mm
Material: PA66+PPE (SE8677)
Machine Tonnage: 208T
Runner : Cold Runner
Availability:
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Application: Electrical Enclosure (Automobile)

Size: 240X190X90mm

Material: PA66+PPE (SE8677)

Machine Tonnage: 208T

Runner : Cold Runner


Injection Molded Electrical Enclosure for Automotive Application



At GoodTech Manufacturing, we excel in delivering customized solutions for injection molded components that meet the rigorous demands of automotive applications. In this case study, we'll explore our collaboration with a client in the automotive industry to develop a durable electrical enclosure using PA66+PPE material, featuring intricate ribbing and side actions.


Introduction:

Our client, a leading automotive manufacturer, required a robust electrical enclosure to house sensitive electronic components in their vehicles. The enclosure needed to withstand mechanical impact, temperature fluctuations, and environmental exposure while ensuring reliable performance and longevity. Leveraging our expertise in injection molding and mold design, we embarked on the challenge of creating a solution that met these demanding requirements.


Challenges of Molding a PA66+PPE Part with Intricate Ribs:

Molding a part with PA66+PPE material and intricate ribbing presents several challenges that must be addressed to achieve optimal results:


Material Properties: PA66+PPE is a high-performance engineering thermoplastic known for its excellent strength, stiffness, and heat resistance. However, it can be prone to shrinkage and warpage during molding, especially in parts with intricate geometries such as ribs.


Flow Balance: Ensuring uniform flow of molten material to all areas of the mold, including the intricate rib structures, is crucial to prevent defects such as incomplete filling, sink marks, or air traps.


Cooling Uniformity: Proper cooling is essential to minimize cycle times and optimize part quality. Achieving uniform cooling across the mold, especially in areas with complex geometries, helps reduce residual stresses and improve dimensional stability.


Mold Design Solutions:

To address the challenges associated with molding a PA66+PPE part with intricate ribs, our team implemented the following mold design solutions:


Cold Runner System: Utilizing a cold runner system allowed for precise control over material flow and minimized material waste. The design of the runner system was optimized to ensure balanced filling of the mold cavity and prevent short shots or inconsistencies in part quality.


Advanced Cooling Channels: We incorporated advanced cooling channels into the mold design to enhance cooling efficiency and minimize cycle times. Strategic placement of cooling channels around the intricate rib structures helped maintain uniform temperatures and reduce the risk of warpage or shrinkage.


Optimized Gate Design: Careful consideration was given to gate placement and design to facilitate smooth material flow and minimize pressure drop. The gate design was optimized to minimize gate vestige and cosmetic imperfections on the finished parts.


Injection Molding Process:

During the injection molding process, our skilled technicians followed a meticulous approach to ensure the production of high-quality electrical enclosures:


Material Preparation: PA66+PPE material was selected for its superior mechanical properties and resistance to environmental factors. The material was carefully dried to the specified moisture content to prevent degradation and ensure optimal processing conditions.


Process Optimization: Injection parameters such as temperature, pressure, injection speed, and hold time were meticulously controlled and optimized to achieve consistent part quality. Real-time monitoring and adjustment of process variables ensured repeatability and reliability throughout production runs.


Mold Maintenance and Inspection: Regular mold maintenance and inspection procedures were implemented to prevent downtime and ensure the longevity of the tooling. Any issues or anomalies were promptly addressed to minimize production disruptions and maintain product quality.


Quality Control:

Stringent quality control measures were implemented at every stage of the manufacturing process to ensure the integrity and performance of the injection molded electrical enclosures:


Dimensional Inspection: Each enclosure underwent thorough dimensional inspection to verify compliance with specified tolerances and ensure proper fitment with other components in the automotive assembly.


Visual Inspection: Visual inspection was conducted to identify any cosmetic defects, such as flash or surface imperfections, and ensure the overall aesthetic quality of the enclosures.


Mechanical Testing: Mechanical testing, including impact resistance and dimensional stability, was performed to validate the durability and performance of the enclosures under real-world conditions.


Through meticulous mold design, precise injection molding processes, and rigorous quality control measures, GoodTech Manufacturing successfully produced injection molded electrical enclosures for automotive applications that met the client's stringent requirements for durability, reliability, and performance. By leveraging our expertise and advanced manufacturing capabilities, we continue to deliver innovative solutions that drive success in the automotive industry and beyond.



 


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