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Freeform Injection Molding
in the automotive industry

Performance car cable bracket

‍The challenge: Insufficient spare parts supply chain.
The solution: Solving digital spare parts manufacturing with 3D printed tooling.

Part design provided by a leading client in the automotive industry.
Using customer specific material, BASF Ultramid 30% Glass-filled PA66.

Part Design(s)
Part Design(s)
3d render of the part design for the cable bracket.
The part design was provided by a leading client in the Automotive Industry. We preferably work with STEP files as input from our clients.
60 minutes
Mold Design(s)‍
3d render of one of the mold parts from a 2 part mold.
Next step is converting the STEP file into a mold design which is done by inverting the part into a cavity, in a block of material, and then adding the inlet gate(s) and initial venting.
5 hours
Printed Tooling
Assembled 2 part mold.
The part size of the design was large. We split the design over 2 mold units and assembled them.
60 minutes
Freeform Injection Molding (FIM)
3d printed mold tool in aluminum tool frame.
The parts were molded on a 50-ton Krauss Maffei. Our molds work hand-in-hand with any installed base molding unit.

An aluminum mold frame was used to hold the large combo mold in place.
2-3 days
Demolding‍
Photo of the final part cable bracket.
The Addifab alkaline solution was used for demolding these parts, over a 2.5 day period.

This can be time-optimized by mold re-design or by removing a part of the mold before demolding.
‍
The bracket above, is the first out of tool: no post-processing, no polishing. Details in design and functionality, stand out clearly. 
Total time to 1st injection molded part:

6 hours 50 minutes +
2-3 days of demolding
Observations

The mold design is an easy process.

The material (BASF Ultramid) seems to fill the molds nicely in the first test rounds.

Optimization for demolding is always a good thing, running the next iterations.
‍
Datasheet materials were used for molding data, settings, pressure, temperatures, and more.

‍Changing Design, Materials, or both - based on obtained results, are just some of the benefits from working with Freeform Injection Molding
Live testing for 9 weeks:
‍3 days after receiving part design
Mounted cable bracket for live testing in high-end sports car.
The parts were mounted in a range of high-end sports cars.

- The part is located directly on top of the Turbo Charger in the engine area.

- They were live-tested for more than 9 weeks.

- Extreme temperature conditions were applied.

- Humidity testing.

- UV testing.

- Vibration testing.

- Mechanical performance testing.

The parts passed all tests.

Technology

One of the Injection Molding machines at Addifab.
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Accelerated development with unseen injection molding tools

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Employee at Addifab, assembling the 3D Printer.
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Contact us for more info on Freeform Injection Molding

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freedom in design
and material

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