Project Background
An electric bicycle manufacturer needed to custom-make a mold for a new battery enclosure. The component featured an irregular shape, required lightweight yet high-strength properties, and had to accommodate battery cell installation and wiring interface layout. These presented numerous technical challenges that the client had failed to resolve with several other suppliers. After taking on the project, we precisely analyzed the technical pain points and achieved targeted breakthroughs: To solve the difficulty of demolding the irregular structure, we optimized the mold parting surface design and adopted a combined structure of angled lifters + core-pulling mechanisms, preventing scratches on the product surface during demolding. To meet the dual requirements of lightweight and high strength, we optimized the mold cavity structure and used special modified materials, reducing weight while ensuring product strength and anti-leakage protection.
In addition, we solved the problem of product deformation caused by uneven mold cooling by optimizing the cooling channel layout to ensure molding accuracy. After multiple rounds of technical debugging, all challenges were successfully overcome. The mold passed trial testing on the first attempt, and the product fully met the client’s technical requirements. This technical breakthrough not only saved the client the cost and time of repeated mold trials, but also helped the client achieve smooth mass production of the new handlebar component. It fully demonstrates our professional strength in the field of mold design and manufacturing.
Project Highlights
- Angled ejector + core-pulling composite structure
- Overcame material and configuration technical challenges
- Successful mass production and supply