CEW Advanced Manufacturing Group Collaborates with a Leading Engineered Components Company to Produce 2,000 Structural Brackets Monthly

Summary

CEW Advanced Manufacturing Group successfully completed an intricate injection molding project for a leading engineered components company, delivering high-quality, precision-engineered components. This case study delves into the project specifics, highlighting the parts’ specifications, uses and applications, manufacturing process, capacity, and quality control measures, showcasing CEW’s expertise in meeting demanding industry standards.

Parts’ Specifications

Material: High-strength, durable thermoplastic, specifically selected for its mechanical properties and resistance to environmental factors.
- Type: Nylon (Pa) with glass fiber reinforcement
Dimensions:
- Component A: 150mm x 100mm x 50mm, with a tolerance of ±0.05mm
- Component B: 200mm x 150mm x 75mm, with a tolerance of ±0.05mm
Design Features:
- Complex geometries with integrated ribbing for structural integrity
- Snap-fit assembly points for ease of integration into larger systems
- Reinforced mounting holes with metal inserts for durability
Press Tonnage:
- 400 tons

Uses and Applications

Industry: Primarily for the transportation and industrial sectors
Function:
- Component A: Used as a structural support bracket in power supply compartments and housing units, designed to endure high vibration, mechanical impacts, and temperature variations
- Component B: Employed as a housing for power control units in industrial equipment and machinery, offering protection against dust, moisture, and mechanical impacts
Benefits:
- Enhanced durability due to the material’s strength and resilience
- Precision engineering ensures perfect fit and function, reducing assembly time and costs
- Long-term performance in harsh operational environments, contributing to the reliability and longevity of the end products

Capacity

Production Volume: CEW’s facility is equipped to handle both low and high-volume production runs, ensuring scalability and flexibility.
- Initial order: 2,000 structural brackets per month
- Potential scalability: Up to 50,000 units per month, with room for expansion
Lead Time:
- Design and prototyping: 1 week
- Tooling development: 1 week
- Production run: 1 week for the initial 2,000 units, with continuous production capabilities
Resource Allocation: Dedicated production lines and automated machinery for high efficiency and consistency
Logistics: Streamlined supply chain and logistics management, ensuring timely delivery and minimizing downtime for the engineered components company

Manufacturing Process

The manufacturing process for the injection molded parts involved several critical steps to ensure precision and quality.

Design and Prototyping

Collaborated with the engineered components company to review designs for manufacturability, utilizing advanced CAD software to simulate and optimize the injection molding process.

Tooling

Evaluated high-precision molds using state-of-the-art CNC machinery, ensuring exacting standards and repeatability.

Injection Molding

Employed high-performance injection molding machines, calibrated for optimal temperature, pressure, and cycle times to produce parts with minimal variance.

Inspection and Packaging

Final Quality Inspection: Perform final quality inspection and validation of products. Packaging: Products are packed in qualified packaging materials.

Quality Control Steps

Inspection Protocols: Implemented rigorous inspection routines at multiple stages of the production process, including in-process checks and final inspection.

Testing: Utilized advanced testing equipment to verify material properties, dimensional accuracy, and performance under simulated operational conditions.

Documentation: Maintained comprehensive records of each production run, ensuring traceability and adherence to the engineered components company’s quality standards.

Conclusion

Through meticulous planning, advanced manufacturing techniques, and stringent quality control, CEW Advanced Manufacturing Group delivered a successful injection molding project for a leading engineered components company, underscoring their capability to meet complex engineering challenges and deliver high-quality solutions. CEW’s commitment to excellence in injection molding positions them as a reliable partner for companies seeking top-tier manufacturing services.