Project details
- Industry: Automotive
- Application: Bumper
- Process: Injection Molding
- Challenge: A company looks for a partner to help produce lightweight bumpers with certain impact resistance in quantity, reducing costs and lowering risks.
To meet their fast-approaching deadline, the company works with Echofast in the large-scale production of bumpers without sacrificing quality and efficiency.
Case Analysis
As an important part of a car, bumper can absorb shock and prevent damage to the body in a collision, further providing drivers with a safe driving environment when driving. It can be made of various materials such as plastics, metals, fiberglass, carbon fiber, etc. Plastic is one of the most common materials for the bumper being lightweight. There are two main kinds of manufacturing processes, and they are injection molding and vacuum forming. However, injection molding is more popular due to its lower cost. The bumper injection mold is a significant tool used to produce large quantities of bumpers, which has extremely demanding requirements for precision and durability. A series of factors should be taken into account to ensure the production efficiency and quality of the bumper. They include the selection of the mold material and plastic material, mold design, injection molding process, and quality control.
Solution
Echofast offers this company custom injection molding services in the production of bumpers. Factors are taken into consideration in mold design to ensure accuracy and consistency, such as the shape, dimension and wall thickness. We provide the company with mold flow analysis and DFM analysis, optimizing the product design and manufacturing process. Because the material of bumper injection mold has requirements for high strength, hardness, wear resistance, and corrosion resistance, we typically use steel like P20, 718, NAK80, and S136. It contributes to enhancing the service life and stability of the mold.
We use PP in automotive injection molding for bumpers, which has a high melting point, corrosion resistance, and low cost. This material is renowned for creating plastic products that demand lightweight properties, toughness, and flexibility.
We carefully set injection molding parameters like temperature, pressure, speed, and cooling time in the process according to the plastic material and mold design. Rigorous quality control is operated in Echofast to manufacture high-quality products on demand, including inspection of raw materials and mold, injection molding monitoring, and the inspection of the final product. We make use of paint to improve the gloss and texture of the bumper surface. We support the company and help them quickly move the project into production.
Product Used
Injection Molding Design & Manufacturing
Outcome
A high-quality injection mold is made by Echofast to manufacture large quantities of lightweight but durable bumpers, ideally minimizing repair costs. It contributes to enhancing the performance of the car, reducing the fuel consumption of the car.
Client Feedback
Echofast helps us resolve DFM issues efficiently through hard work and dedication, streamlining the process to get what we need. We know we can count on them in that they can provide instant pricing and lead times.
