Custom automotive plastic injection molded components engineered for interior, exterior, and under-the-hood systems. Built to strict OEM and Tier 1 design criteria, focusing on dimensional stability, structural integrity, and long-term environmental resistance.
Technical Specifications
|
Parameter |
Specification Range |
|
Dimensional Tolerance |
Standard ±0.1 mm; Precision ±0.03 mm to ±0.05 mm (GD&T compliant) |
|
Clamping Force |
80T to 1,600T servo-driven injection presses |
|
Shot Weight Capacity |
10 g to 3,500 g |
|
Cavitation |
Single-cavity to 64-cavity configurations with hot/cold runner systems |
|
Surface Texture & Finish |
VDI 3400, SPI (A1 to D3), high-gloss, and chemical etching |
|
Quality Framework |
IATF 16949 certified, ISO 9001, PPAP Level 1–3 support |
Key Features
Tight Tolerance Control: Closed-loop machine monitoring maintains critical dimensions across high-volume production runs without secondary machining.
Optimized Gate Locations: Mold flow simulation identifies and resolves potential weld lines and air traps in structural or cosmetic zones.
Shot-to-Shot Consistency: Servo-electric dosing and melt pressure feedback prevent flash, short shots, and sink marks.
Traceability: Laser-etched cavity markers and batch codes on parts for raw material and production tracking.
Materials & Options
PA6, PA66 (with 15%–30% glass fiber), PC, ABS, PC/ABS, PP (talc-filled or unfilled), POM, PBT, TPE, and TPU.
UV-stabilized grades for exterior components, flame-retardant compounds (UL94 V-0) for electrical enclosures, and high-heat formulations for engine bays.
Masterbatch compounding matched to strict OEM interior and exterior color standards.
Manufacturing Process
DFM & Mold Flow Analysis: Engineering review evaluating draft angles, wall thickness uniformity, and gate placement prior to cutting steel.
Tooling Fabrication: CNC machining, high-speed milling, EDM, and wire cutting using P20, H13, or NAK80 tool steel.
Trial Sampling (T1/T2): Initial sampling runs to verify dimensions, shrinkage rates, and mechanical fit against mating parts.
Mass Production: Automated injection molding integrated with robotic part removal, sprue separation, and inline cooling fixtures.
Secondary Operations: Ultrasonic welding, pad printing, laser etching, and sub-assembly integration.
Quality Control & Metrology
CMM Inspection: 3D coordinate measuring machines verify complex geometries, positional tolerances, and true position.
Material Verification: Melt flow index (MFI) testing, moisture analysis, and density checks on incoming resin lots.
Process Logging: Real-time data logging on injection pressure, melt temperature, and cooling time for every shot.
PPAP Documentation: Comprehensive PPAP packages (Dimensional results, Material CoAs, FMEA, Control Plan) prepared per customer requirements.
Customization & Secondary Services
Insert & Over-Molding: Encapsulating metal inserts, threaded studs, stamped brackets, or multi-shot elastomeric grips.
Texture & Gloss Execution: Precision mold polishing and chemical etching to achieve exact tactile surfaces for interior touchpoints.
Custom Packaging: ESD-safe trays, returnable dunnage, or automated bulk packing configured for direct automated assembly line feed.
Applications
Interior Trim:
Instrument panel skeletons, center consoles, air delivery vents, and glove box assemblies.
Exterior Components:
Bumper grilles, exterior mirror housings, cowl grilles, and aerodynamic body clips.
Under-the-Hood:
Fluid reservoirs, sensor brackets, fuse box covers, and air intake manifolds.
Electrical & Connectors:
Multi-pin connector housings, relay holders, and wire harness management clips.
Packaging & Delivery
Protective Packaging: Individually layered in honeycomb cardboard separators or custom thermoformed trays to prevent transit scuffs and deformation.
Logistics Support: Direct export via sea freight (FCL/LCL) or air cargo from major ports; local safety stock agreements available for scheduled call-off inventories.
FAQ
Q: What 3D CAD formats do you accept for DFM and quoting?
A: We accept STEP, IGES, Parasolid, and native SolidWorks or CATIA files alongside 2D drawings with complete GD&T callouts.
Q: What is your typical tooling lead time?
A: Standard tooling fabrication ranges from 3 to 6 weeks depending on mold complexity, cavity count, and selected tool steel.
Q: Can you provide full PPAP Level 3 documentation?
A: Yes. Complete PPAP packages including dimensional inspection reports, material certificates of analysis, and process flow diagrams are standard for automotive validation.
Q: What is your minimum order quantity (MOQ) for production runs?
A: MOQ is determined by annual volume commitments and raw material resin lots, typically starting at 1,000 to 5,000 pieces per run.
Q: How do you manage tool maintenance and ownership?
A: Customer-owned tooling remains your proprietary asset. We perform scheduled preventive maintenance (ultrasonic cleaning, venting, and lubrication) every 50,000 cycles at no additional charge.
Q: How do you verify raw material authenticity?
A: All engineering resins arrive with manufacturer Certificates of Analysis (CoA) matching certified automotive specifications.
Request a Quote
Submit your 3D CAD files, estimated annual volume, material grade, and delivery schedule to receive a DFM engineering report and tooling quotation within 24 hours.
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