All Case Studies
AutomotiveDFM + Injection Mold Design
ADAS Sensor Enclosure DFM
Client: AutoDrive Systems
<1%
Scrap Rate
18 Sec
Cycle Time
50k+
Units/Month
01. Requirement
Project Scope & Objectives
Design and manufacture a robust, IP67-rated enclosure for a high-resolution LiDAR sensor used in autonomous vehicle test fleets.
02. Challenges
Technical Hurdles
Initial designs suffered from thermal throttling and moisture ingress. The complex geometry made traditional parting lines difficult to manage without flash.
03. Solution
Our Engineering Approach
Redesigned the internal heat sink integration and applied strict DFM principles to the mold parting lines. Developed a custom TPE overmold for the sealing surface.
Key Technologies Applied
Injection MoldingDFMIP67Automotive
04. Results
Measurable Impact
Achieved zero moisture ingress during rigorous 1000-hour humidity testing. The optimized cycle time reduced unit production cost by 22% compared to the previous version.
Production-ready CAD files delivered ahead of schedule.
Achieved all structural and regulatory certifications.
Technical Specifications
Material
PC/ABS + TPE
Mold Material
P20 Steel
Seal Rating
IP67 / IP69K
Process Timeline
DFM Analysis3 Days
Mold Design5 Days
T1 Sampling14 Days
Mass ProductionOngoing
Key Deliverables
- Injection Molds
- Production Samples
- IP67 Test Report
- QC Documentation
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