Project Overview
A Tier-1 automotive supplier required metal replacement for weight reduction. The project demanded high strength, temperature resistance, and significant weight savings.
Challenge
- Weight Reduction: 40% savings vs. aluminum target
- Strength: Equivalent structural performance to metal
- Temperature: Under-hood temperatures up to 150°C
- IATF Certification: Automotive quality requirements
- Cost: Lower cost than metal alternative
Solution
Material & Design
- PA66-GF30 for strength and temperature resistance
- Topology optimization for minimum weight
- Rib design for structural stiffness
- Metal insert molding for threaded connections
Quality Systems
- IATF 16949 certified processes
- Mechanical testing per automotive standards
- Temperature cycling validation
- Long-term creep testing
Results
| Metric | Target | Achieved |
|---|---|---|
| Weight Reduction | 35% | 40% |
| Strength | Equivalent to metal | Exceeded |
| Temperature | 140°C | 150°C |
| Certification | IATF 16949 | Achieved |
| Cost Reduction | 20% | 30% |
Customer Testimonial
“CoreLMould’s metal replacement exceeded expectations. 40% weight savings, stronger than aluminum, and 30% cost reduction. Game-changer for our platform.”
- Chief Engineer, Tier-1 Automotive Supplier