Specialist in communication solutions seeks specialist in plastic solutions
Preventing a Production Halt
For years, our client was able to receive a plastic component directly from stock. However, with the expectation that no more parts were needed, the mold was scrapped by the previous supplier.
In search of an affordable solution that would allow them to deliver the last production series within the promised delivery date, they turned to us.
The Challenge
- Functional design with a good fit on the printed circuit board;
- Heat resistant, flame retardant, and strong;
- Affordable solution for a small series;
- From design to production within six weeks.
The Solution
The component is designed to guide towards the print connector. Therefore, it needed to accommodate both a mounting point on the PCB and smooth guidance to the connector.
In the design phase, the component was split into two mirrored halves that can be joined via a snap-fit connection. This keeps the mold simple while ensuring the product still meets the required specifications. A tapered lead-in guarantees guidance towards the connector, and an opening on top allows the component to be mounted on the PCB.
The mold is by far the most expensive part of the project and can significantly increase costs for a small production run. The primary factors influencing the cost of an injection mold are the size and complexity of the part, as well as the number of parts being produced. We considered complexity during the design process, allowing us to reduce the final mold costs.
Several options for the type of mold were evaluated based on cost and lead time. Ultimately, we chose to produce only the core inserts and an ejector package, leaving out the remaining steel, also known as the mold base, thus saving on materials.
Electrical properties, heat resistance, and flame retardancy are critical in an enclosure with multiple PCBs. For this reason, we selected a blend of PPO and polystyrene, a material with high heat resistance, good electrical properties, and dimensional stability.
The final step was the actual production. As an injection molder, we handled the production. For any new or existing molds, we ensure a machine is available to start production immediately.
The Result
The customer does not have to worry about all the technical aspects because we guide the entire process from A to Z. This allows them to focus more on what is important.
Ultimately, we were able to prevent a production halt by completing the entire process within six weeks. But even more importantly, a satisfied customer:
Fleur Plastics is collaborative, has a very strong problem-solving ability, and is super flexible. Excellent quality at a great pace and very pleasant to work with.
Rene Passchier - Senior Buyer
