Job Specification:

Project: Audi Plastic Parts “Liquid Trap C7 Phev”

Processes: Mold Manufacturing & Plastic Injection Molding

Materials: P20 (Old Mold Base); Lupolen GX 5038(Part) 

Lead Time: 12 days

Quantity: 1000-1500 Units

ld deliver fast – in 12 days the mold was finished and the first

Designer and Project Specs:

Our customers,Dr.Henri-Jacques-Topf (Chief Executive),Craig

Harden(Project Manager), Falk Haarig(Purchasing Agent), of

Schneider Company build some of the finest comfort and

convenience car parts for the Audi Automation Germany,They

often made mold from Europe,USA, but the prices is very

higher.and delivery time is too long.which is why the guys from

Schneider Company started looking for new options in Asia. They

have Visit more than 100 factoys in China,but Finally ,They choose

Vowin as they Supplier.Vowin have good Experience of

Automative area. Vowin have work with Landrover and Jaguar

more than 10years. Vowin offered the same quality of parts but at

a lower cost – and most importantly: Vowin could deliver fast – in

15 days the mold was finished and the first test run was

completed. So The Schneider Company have Enough time to

assembly the parts for Audi.supply of the visor products.ns in Asia.

STAR offered the same quality of parts but at a lower cost – and

most importantly: STAR could deliver fast – in 12 days the mold

was

Before make the mold. Schneider Company tell us many times.

This part are very difficult to make it.The Inside Silder must be very

Striaght.They have make Silimar Parts Before in Germany.But the

parts not working well. So they really need a nice part with low

Cost ,fast delivery time and Good Service.

Mold Build:

For this project we need to make two parts of different shapes. Our

goal is to make both parts in the same mold to safe time and cost.

The challenge here is the wall-thickness of the fairly long tube-

shaped part – it is just 0.5mm.

Step 1-Confirm the mold design,

Make DFM to Schneider Company Confirm the mold design,to

make sure everything is right.

Step 2– Verify Mold Material

We want to build the mold fast which is why we use P20(Old Mold

base)– it is very easy to machine and low cost. First we need find

the silimar mold base size with the parts. and verify the material in

our inspection department using a Optical Emission Spectrometer

(OES). We need to be very careful with the old mold base we used

.Therefore we inspect everything before machining it. After

verifying the mold material, we use Electrical Discharge Machining

(EDM) to make the cavities.

Step 3 – Electrical Discharge Machining (EDM) &

Polishing of Cavities

As mentioned above we make a 1+1 mold . The two cavities

require a total of 10 electrodes. After the EDM part is done we still

need to finish the cavities by hand. In order to achieve a smooth

surface finish on the parts we hand-polish the cavities until the

surfaces are all smooth and to the specification of our customer.

The mold is not finished yet, since we still require the hand loaded

inserts.

Step 4– Machining of Hand Loaded Inserts for the

Cavities

We use CNC machining to make the hand-loaded inserts. The

reason we use hand-loaded inserts in this mold (and not automatic

sliders) is that our customer produces a limited amount of units

(1000 units) and is on a very tight schedule. Hand-loaded inserts

allow our customer to substantially decrease the build time for the

mold as well as the cost for the mold. The quality of the parts

however remains very high.

Step 5 – Molding of Parts

We assemble the finished mold in a mold base and install it in a

plastic injection molding machine. Afterwards we test-inject the

parts in Lupolen GX 5038 material.

Step 6:Accord 2D design and 3D design make the test

report

After the test run we inspect the parts and present them to our

customer. Only after their approval will we start production of the

batch.

Customer Feedback:

I have been impressed by the team at Vowin Prototype every

step of the way. The workmanship and product quality has

been consistently excellent, while their initial thinking in terms

of translucency helped enhanced the visual appeal of the

isostick.

Craig Harden

Business Development & Project Manager