Project Overview
A power tool manufacturer required lightweight motor housings for improved ergonomics. The project demanded high strength, heat resistance, and significant weight reduction.
Challenge
- Weight Reduction: 30% savings for improved ergonomics
- Strength: Equivalent to metal for motor mounting
- Heat Resistance: Motor heat up to 120°C
- Impact Resistance: Job site durability requirements
- Cost: Competitive with metal alternative
Solution
Material & Design
- PC-GF20 (20% Glass-Filled Polycarbonate)
- Optimized wall thickness for strength and weight
- Integrated motor mounting features
- Ventilation design for heat dissipation
Testing & Validation
- Structural FEA analysis
- Heat resistance testing
- Drop testing for durability
- Long-term motor mounting validation
Results
| Metric | Target | Achieved |
|---|---|---|
| Weight Reduction | 25% | 30% |
| Strength | Equivalent to metal | Exceeded |
| Temperature | 100°C | 120°C |
| Annual Volume | 200K units | 500K+ units |
| User Comfort | 8/10 | 9.5/10 |
Customer Testimonial
“CoreLMould’s PC-GF20 motor housings transformed our tool ergonomics. 30% lighter, stronger than metal, and user comfort ratings increased significantly.”
- Product Manager, Power Tool Manufacturer