Project Background
The client is a Tier 1 supplier to Ford New Energy. They are primarily responsible for the development and production of electrical system components. This project involves fuse box housings for the electric power systems of new energy vehicles. The product has a complex structure and requires high insulation, high temperature resistance, and strong impact resistance.
Fuse boxes operate in high-voltage, high-temperature environments within electric power systems. This places extremely high demands on mold dimensional accuracy, material shrinkage control, and assembly tolerances. The client ultimately chose to collaborate with GBM to develop this high-precision injection mold.
Our Solution
1. Mold Design and Engineering Analysis
The GBM team conducted mold flow analysis in the early stages of the project. We optimized the gate location and cooling system. This effectively prevented shrinkage marks and warpage. The mold employs a multi-cavity hot runner design to ensure balanced material flow.
We also implemented a high-precision insert and slider system to ensure demolding accuracy for the complex structure.
2. Material Selection and Performance Control
We selected reinforced nylon PA66+GF30 as the main material for the fuse box. This material possesses excellent mechanical strength and heat resistance. During the molding process, GBM strictly controls injection temperature and pressure to prevent glass fibers from floating to the surface, causing roughness or silver streaks (silver-white streaks caused by residual gas).
3. Quality and Validation
Mold component precision is controlled within ±0.005mm.
Products pass high-temperature aging, voltage breakdown, and assembly tests.
Mold life: Over 1,000,000 cycles
4. Engineering Highlights
The GBM team uses a special wear-resistant alloy steel material in the mold guide structure to improve mold life. This also reserves an interface for future automated production, meeting the customer’s future automated injection molding needs.
Project Results
- Mold manufacturing cycle: 42 days
- First-time trial pass rate: 100%
- Product yield: 99.8%
- Mold life: >1,000,000 cycles
- Customer feedback: GBM’s mold precision and delivery speed exceeded expectations, and the project was successfully put into mass production.
