Planned warping? Sounds bad—works well

Posted by Al Elger on Oct 24, 2011 2:00:00 PM

blank.pngMolding parts used in exterior, weather-sensitive, and/or high-impact applications requires the ability to undertake and solve significant challenges. Parts that need to function in such environments are prone to warping in the molding process. However, the right engineering partner can plan and account for such potential exigencies in the manufacturing process, before they surface in assembly and usage.

While just about any industry has the potential need for parts that meet the above performance requirements, the automotive sector illustrates particular challenges encompassing all three.

Sunroof deflectors, for example, must be made of especially strong and chemical-resistant material in order to hold their shape at high speed and withstand the elements—no matter the climate in which the vehicle is driven The type of rigid nylon needed for this application, though, presents a challenge: it is high in fiberglass and these fibers warp when the part leaves the mold. So it must actually be molded with precise distortion—planned warping—in the other direction so that it warps into its proper shape after molding.

Kaysun has successfully utilized this planned warping procedure in various critical vehicle parts, including valve controls for air-activated brakes in heavy trucks and idler pulleys used in the engine compartment of most passenger cars. While a flaw in a sunroof deflector could mean part failure or excessive noise, a flaw in a valve control could mean loss of life. We usually use the term “critical use” when referring to our medical and defense projects, but automotive and industrial applications can be just as critical when part failure could result in injury or death.

The expertise of our engineering team allows us to predict the polymers’ behavior not only in terms of planned warping, but also in initial material selection, tool design, assembly/finishing, and other considerations to ensure long-term, reliable performance of these essential parts. Please contact us early in your development process for maximum efficiency and optimum results.

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