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Front Water Channel for Automotive
For a leading automotive sunroof supplier, DYNAMIK LABS was selected to develop a front water channel mold (VW‑PSDB4) with extremely tight dimensional and tolerance requirements in PP GF40. The customer needed a robust 1K serial tool capable of a 65‑second cycle time, built for a 650‑ton machine, and designed for long life in mass production. Any warpage or dimensional drift would directly affect the sealing performance of the sunroof system, so simulation‑driven design and precise tooling were critical.
Case studies
DYNAMIK LABS engineered a 1K insert overmolding mold measuring 1600 × 900 × 921 mm (7,500 kg), where pre‑formed inserts are loaded into the tool and then overmolded with plastic to create a single, integrated component and eliminate secondary assembly. The tool integrates multiple lifters and sliders to form the detailed water channel geometry while keeping the inserts accurately located and fully encapsulated. Using moldflow analysis and dedicated checking fixtures, the team optimized gating, cooling, and part support to control deflection within the required profile tolerance, achieving around 85% dimensional accuracy already at T1 and reducing tuning time for the customer.
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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