-55%
Tooling Cost
14 Days
T1 Delivery
10k Units
Part Life
01. Requirement
Project Scope & Objectives
The client needed 5,000 units of an EV charger housing within 3 weeks for a pilot infrastructure project, making traditional steel tooling too slow and expensive.
02. Challenges
Technical Hurdles
The material (PC/ABS) required high injection pressures, which can be challenging for traditional rapid tooling materials like soft resins.
03. Solution
Our Engineering Approach
Manufactured a high-strength aluminum mold (7075-T6 alloy) with a specialized cooling circuit to optimize cycle times for the pilot production run.
Key Technologies Applied
Rapid ToolingAluminum MoldEV ChargerPC/ABS
04. Results
Measurable Impact
Delivered T1 samples in 14 days. Saved the client over $40,000 in tooling costs while providing production-quality parts that met all flame-retardancy (UL94-V0) standards.
Production-ready CAD files delivered ahead of schedule.
Achieved all structural and regulatory certifications.
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