Custom Injection Molded Lever Plate Development For Automotive

Injection molded Mercedes Parking Gear Lever Plate Development

In our collaboration with clients, we remain focused on striving for excellence. The Mercedes parking gear lever plate project is a prime example that not only demonstrates our exceptional engineering expertise but also highlights our scientific and efficient project management.

Product Requirements and Challenges

The Mercedes parking gear lever plate is a typical double-shot injection moulded product, combining complex aesthetics with stringent performance requirements. The first shot is made from white PC (polycarbonate), and the key challenge is to maintain the logo’s perfect shape during the second injection, while also withstanding the high temperatures involved. Additionally, the white PC must have sufficient adhesion to ensure a firm bond with the second shot, which is a black PC/ABS (polycarbonate/acrylonitrile-butadiene-styrene) material.

After the second shot, the entire product needs to display an exceptional aesthetic effect, with the white logo standing out clearly against the black background, retaining its shape, gloss, and details. Beyond its visual appeal, the product must meet high standards for durability and functionality.

Formation of a Specialised Technical Team

To meet these demanding product requirements, we formed a specialised team with extensive experience in handling complex double-shot moulding processes. At the start of the project, we held thorough technical discussions, drawing on lessons from past projects and carefully analysing each detail, particularly focusing on product design, mould structure, and material properties.

Through a systematic PFMEA (Process Failure Mode and Effects Analysis), we mapped out a comprehensive technical route, identifying key risk factors and potential failure modes. Based on this analysis, we developed detailed risk management strategies. During the DFM (Design for Manufacture) phase, we discussed and refined the mould structure, venting methods, and runner design. These proposals were then reviewed and approved in collaboration with the client.

Design Optimisation and Collaboration

Throughout the project, we maintained close collaboration with the client. During the design phase, we conducted multiple rounds of optimisation, working together to review and improve every detail. This ensured the product not only met its design expectations but also optimised its manufacturing process and cost efficiency.

By continuously providing feedback and making adjustments, we not only enhanced the product’s visual design but also ensured smooth coordination between various stages of the manufacturing process. This high level of efficient, transparent communication gave the client great confidence in our work and earned our team high praise for our professionalism.

Scientific Management and Smooth Development

During the project implementation phase, we adhered to strict scientific project management practices. We held weekly meetings with the client to provide timely updates on progress and ensure any issues were addressed immediately. This continuous interaction ensured that the project remained on track, fostering a strong sense of trust between us and the client.

Throughout the project, the client consistently recognised and appreciated our efforts, praising our team for its professionalism, technical solutions, and execution. This positive collaboration laid a solid foundation for the successful completion of the project.

Mould Trials and Final Results

In the mould trial phase, every aspect of the project was meticulously tested. Through careful process control, we ensured that every detail was flawlessly executed. After receiving feedback from the first mould trial, we made some minor adjustments, and the second trial exceeded client expectations. The product’s appearance, translucency, logo contours, and gloss were perfectly achieved. The client expressed immense satisfaction with the final result, especially noting the precision and craftsmanship of our work.

Every client who collaborated with us on this project has given it glowing reviews, recognising that our product not only meets top-tier technical standards but also reflects an exemplary level of service.

Ongoing Collaboration and the Pursuit of Excellence

Our collaboration with Mercedes extends beyond this project. We have worked together on several projects, and Mercedes demands the highest standards for quality systems from their suppliers. Each generation of products pushes the boundaries of technology and pursues excellence. We fully understand their rigorous expectations for innovation and quality, and in every collaboration, we strive to stay in step with their goals. This pursuit of excellence aligns perfectly with FCE’s core mission.

FCE Injection Moulding Services

FCE is committed to providing clients with cutting-edge injection moulding services, including precision injection moulding, double-shot moulding, gas-assisted moulding, and in-mould decoration (IMD). Our efficient service team has earned the trust of many discerning clients who value quality and strive for excellence. Through our unwavering commitment to technical innovation and quality, FCE consistently delivers high-quality solutions, helping our clients achieve outstanding product designs and maintain strong market competitiveness.

This collaborative journey with Mercedes showcases our relentless pursuit of excellence and innovation, and it stands as a testament to FCE’s commitment to growing and succeeding alongside our clients.