How to Design the product

1. 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
SchneiderCompany build some of the finest comfortand
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
SchneiderCompany 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

2. mold was finished and the first test run was completed.So The
SchneiderCompany have Enough time to assemblythe parts for
Audi.supply of the visor products.ns in Asia. STAR offered the same
quality of parts but at a lower cost – and mostimportantly: STAR
could deliver fast – in 12 days the mold was
Before make the mold. SchneiderCompany 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 differentshapes.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.

3. Step 1-Confirm the mold design,
Make DFM to Schneider Company Confirm the mold design,to
make sure everything is right.

4. 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 inspectiondepartment using a Optical EmissionSpectrometer
(OES). We need to be very careful with the old mold base we
used .Therefore we inspecteverything before machining it. After
verifying the mold material, we use Electrical Discharge Machining
(EDM) to make the cavities.

5. 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.Afterthe EDM part is done we still
need to finish the cavities by hand. In orderto achieve a smooth
surface finish on the parts we hand-polish the cavities until the
surfaces are all smoothand to the specificationof our customer.
The mold is not finished yet, since we still require the hand loaded
inserts.

6. 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 customerproduces alimited amount of units
(1000 units) and is on a very tight schedule.Hand-loaded inserts
allow our customerto substantially decrease the build time for the
mold as well as the costfor the mold.The quality of the parts
however remains very high.

7. 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.

8. Step 6:Accord 2D design and 3D design make the
test report
After the test run we inspect the parts and presentthem to our
customer.Only after their approval will we start production of the
batch.

9. 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