Project Overview
A Tier-1 automotive supplier required lightweight intake manifolds for a new engine platform. The project demanded high temperature resistance, pressure containment, and significant weight reduction vs. traditional aluminum construction.
Challenge
The primary challenges included:
- High Temperature: Must withstand under-hood temperatures up to 150°C
- Pressure Containment: Internal pressure up to 2 bar boost pressure
- Weight Reduction: 40% weight savings vs. aluminum target
- IATF Certification: IATF 16949 automotive quality requirements
- Vibration Welding: Two-piece manifold assembly requiring precision welding
Solution
Our engineering team developed a comprehensive solution:
Material Selection
- PA66-GF30 (30% Glass-Filled Nylon 66) for high strength and temperature resistance
- Excellent creep resistance for long-term pressure containment
- Good chemical resistance for under-hood environment
Design Optimization
- Topology optimization for minimum weight with required strength
- Rib design for stiffness and pressure containment
- Optimized wall thickness for uniform cooling
- Vibration weld joint design for strong assembly
Manufacturing Process
- Large tonnage injection molding machines for manifold size
- Vibration welding equipment for precise assembly
- Leak testing on 100% of production units
- CMM verification of critical dimensions
Results
The project exceeded all targets:
| Metric | Target | Achieved |
|---|---|---|
| Weight Reduction | 35% | 40% |
| Temperature Rating | 140°C | 150°C |
| PPAP Status | Approved | Approved (First Pass) |
| Production Volume | 200K units | 500K+ units |
| Field Failures | 0 | 0 |
Key Success Factors
- Material Expertise: PA66-GF30 selection for optimal performance
- Design Excellence: Topology optimization achieving weight targets
- Quality Systems: IATF 16949 processes ensuring zero defects
- Testing Rigor: 100% leak testing ensuring product integrity
Customer Testimonial
“CoreLMould’s glass-filled nylon intake manifolds exceeded our expectations. 40% weight reduction with perfect PPAP approval and zero failures in 500K+ units. Their automotive capabilities are world-class.”
- Engineering Director, Tier-1 Automotive Supplier