Project Overview
An automotive sensor manufacturer required precision insert molding of sensor housings with embedded brass inserts. The project demanded IATF 16949 certification, precise insert placement, and environmental sealing for automotive operating conditions.
Challenge
The primary challenges included:
- Automotive Certification: IATF 16949 quality system requirements
- Insert Precision: Brass inserts must be positioned within ±0.05mm
- Environmental Sealing: Must withstand temperature extremes and moisture
- High Temperature: PPA material for under-hood applications (150°C+)
- PPAP Documentation: Full Production Part Approval Process documentation
Solution
Our engineering team developed a comprehensive solution:
Insert Molding Process
- Automated insert placement system for consistent positioning
- Custom fixtures to hold inserts during molding
- Process monitoring for insert displacement detection
- Vision system for post-mold insert verification
Material Selection
- PPA (Polyphthalamide) for high-temperature resistance
- Excellent chemical resistance for automotive fluids
- Low moisture absorption for dimensional stability
Quality Systems
- IATF 16949 certified manufacturing processes
- PPAP Level 3 documentation package
- SPC on all critical dimensions
- 100% insert position verification
Results
The project exceeded all targets:
| Metric | Target | Achieved |
|---|---|---|
| Annual Volume | 500K units | 1M+ units |
| Insert Precision | ±0.1mm | ±0.03mm |
| Quality Escapes | <50 PPM | 0 PPM |
| PPAP Status | Approved | Approved (First Pass) |
| On-Time Delivery | 98% | 100% |
Key Success Factors
- Automation: Automated insert placement ensuring consistent precision
- Material Expertise: PPA selection for demanding under-hood conditions
- Quality Focus: IATF 16949 systems delivering zero-defect performance
- Documentation: Complete PPAP package approved on first submission
Customer Testimonial
“CoreLMould’s insert molding capabilities and IATF 16949 certification make them an ideal automotive partner. They’ve delivered 1M+ sensor housings with zero defects and perfect PPAP approval.”
- Manufacturing Director, Automotive Sensor Manufacturer