Search
View All Categories
Door Lock Controller Product 02

Door Lock Controller Product 02

Prev

No data

Door Lock Controller Product 02
Door Lock Controller Product 02
Door Lock Controller Product 02
Door Lock Controller Product 02
Door Lock Controller Product 02
Door Lock Controller Product 02
Door Lock Controller Product 02

Model:

2020 Tesla Model Y (U.S. Version)

Project Model:

Model Y

Product Type:

Front and rear door lock control module—lower cover. Due to the competitor’s inability to meet Tesla’s stringent quality requirements, its product has consistently suffered from deformation issues that have yet to be fully resolved, resulting in the component being classified as “special procurement” and failing Tesla’s PPAP approval. Our company collaborated with this U.S. customer by leveraging advanced mold engineering design and manufacturing, coupled with state-of-the-art injection molding technology, to deliver a high-quality product that perfectly conforms to Tesla’s drawing specifications. The dimensional accuracy exceeds the customer’s requirements, enabling the component to pass mass-production approval on the first attempt and helping the customer gain a competitive edge in this market segment.

Door Lock Controller Product 02
Door Lock Controller Product 02
Door Lock Controller Product 02
Door Lock Controller Product 02
Door Lock Controller Product 02
Door Lock Controller Product 02

HeYao Technology, a leading player in the automotive components industry, is honored to have commenced discussions on this challenging mold project in 2019. Both sets of interlocking door-lock housings are manufactured using 2+2 cavity molds.

 

The primary challenges in designing this lock housing lie in deformation control and poor flow during molding, compounded by its complex geometry. The housing is made from a PBT+GF material, which, although exhibiting low shrinkage, contains a high glass-fiber content that results in poor flow. Moreover, the intricate part geometry further complicates gate placement and injection molding, increasing the likelihood of warpage and distortion. To address these issues, our company employs advanced pre-deformation simulation analysis to precisely quantify deformation allowances and translate these findings into process parameters. These parameters are then incorporated into mold design to enable precise control over anisotropic shrinkage across all directions. Combined with meticulous machining tolerances and optimized injection-molding practices, we conduct extensive parameter optimization during the T0 development phase. Subsequent optical scanning and CMM measurements are used to identify the optimal injection-molding settings, which serve as the basis for precision mold adjustments. Each subsequent trial mold is run using these stabilized processing parameters, and after three rounds of trials, the final mold is validated when all dimensions meet specifications and critical dimensions achieve a CPK value of at least 1.67.