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Battery Cover for Automotive
For a global automotive customer, DYNAMIK LABS was tasked with developing a high‑cavitation mold for a battery cover in PA6 FR(30). The key challenge was to achieve excellent flatness across all parts, while designing an 8‑cavity solution fully compatible with the customer’s existing 650‑ton injection molding machine. With a target production cycle time of 50 seconds and a required tool life of 1,000,000 shots, the customer needed a tooling partner that could balance output, precision, and long‑term reliability.
DYNAMIK LABS designed a 4+4 stack tool measuring 1200 × 990 × 1147 mm (9,840 kg), enabling double‑sided production to maximize cavitation and improve overall productivity per machine hour. In parallel, the team developed customized robot hands tailored to the part and runner layout, ensuring stable demolding, secure part handling, and smooth integration with the customer’s automation system. These robot hands support consistent part removal and handling, helping to achieve and maintain optimal cycle time while protecting the molded parts from deformation or damage. Optimized cooling circuits, a 24‑nozzle manifold, and dedicated checking fixtures were used to control warpage and verify flatness and key dimensions, achieving around 85% dimensional accuracy already at T1 and minimizing tuning loops.
Despite a challenging specification, the project was completed ahead of schedule. Against a planned lead time of 12 weeks, DYNAMIK LABS delivered the mold in 11 weeks while guaranteeing a tool life of 1,000,000 shots. The production cycle time target of 65 seconds was reached in mass production, and warpage was kept within the agreed profile limits, ensuring consistent sealing performance for the sunroof assembly. This project demonstrates DYNAMIK LABS’ capability to handle complex insert‑overmolded automotive components, combining engineering simulation, precision machining, and efficient project management to reduce time‑to‑SOP for OEM and Tier‑1 customers.
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