Customized Plastic Housing for Automotive Radar

2024-03-07




Manufacturing Service: DFM Report, Injection Mold Design, Plastic Mold Making, Plastic Injection Molding.


Plastic Material: PBT+GF30


Mold Steel: S136


Mold Cavity: 1*2


Surface Treatment: Texture (VDI 27)






About this Project


Frico is a client from Germany who contacted our company in August 2023 through the website. His project is extremely urgent and requires us to complete a large-scale production of radar casings for automobiles within one month. The project's objective is to produce radar casings made of PBT+GF30 material that meets the required fire resistance specifications.



After confirming the material, application, and surface treatment requirements with the client, we provided the product quotation and material data sheet within 24 hours. Subsequently, we updated the client weekly on the progress of the project and addressed any issues that arose during the course of the project.








Design For Manufacturing Review


After receiving Frico’s 3D design drawings for the product, engineers will create a Design for Manufacturing (DFM) report. Our mold engineer identified some potential injection molding issues, such as excessive thickness in certain areas of the product structure and an excessive amount of adhesive in the self-tapping screw holes, which might result in sink marks on the product after injection molding.










Injection Mold Making and Prototype Test


After the communication, our engineers began the mold design and created a prototype for verification.



A. Mold design approval and material ordering - After the customer confirms the mold drawings, we start ordering the required steel and provide weekly updates on the mold progress report and processing pictures.



B. Accelerate mold manufacturing - By the third week of August, we have completed the CNC machining and quenching operations for the mold.



C. Precision machining - By the fourth week of August, we have finished the CNC precision machining and carried out wire cutting and copper electrode manufacturing.



D. Mold polishing and EDM machining - By the end of August, the front mold is undergoing polishing, while the thin bone section of mold core (approximately 30 millimeters) requires careful EDM machining to avoid deformation. According to the mold department's report, the back mold will be ready by September 1st.





E. Mold trial - In the first week of September, the mold will be ready for trial testing.









Conclusion


Throughout the project, we had close collaboration with the client, mold engineers, injection engineers, and project managers, working together to resolve issues and enhance product quality. In the end, we successfully delivered the products that met the client's requirements, earning their trust and satisfaction.