Project Overview
An automotive component supplier required self-lubricating gears for window regulator mechanisms. The project demanded wear resistance, noise reduction, and elimination of external lubrication.
Challenge
- Wear Resistance: Long service life without lubrication
- Self-Lubricating: No external lubrication required
- Noise Reduction: Quieter operation vs. metal gears
- Temperature: Under-vehicle temperature range (-40°C to 80°C)
- Cost: Lower cost than metal with lubrication
Solution
Material Excellence
- Nylon PA66 with self-lubricating additives
- MOS2 (Molybdenum Disulfide) for enhanced lubrication
- Optimized formulation for wear resistance
Design & Testing
- Optimized gear tooth profiles
- Wear testing under simulated conditions
- Noise testing and validation
- Temperature cycling validation
Results
| Metric | Target | Achieved |
|---|---|---|
| Part Life | 2x metal | 3x metal |
| Noise Reduction | 25% | 40% |
| Lubrication | Eliminated | Eliminated |
| Annual Volume | 500K units | 1M+ units |
| Cost Savings | 20% | 35% |
Customer Testimonial
“CoreLMould’s self-lubricating nylon gears are brilliant. 3x longer life than metal, 40% quieter, and no lubrication needed. Perfect for automotive applications.”
- Engineering Manager, Automotive Component Supplier