Base Connector for Automotive Mirror Switch

Competitive component price and increased reliability made possible with superior insert molding . This was a case where domestic manufacturing proved more competitive than a foreign production source, even with the reduced foreign labor cost.

The customer awarded Microplastics this project because Microplastics' insert molding process proved faster, with significantly lower insert fall-out, compared with the customer's insert molding capabilities at a Mexican manufacturing facility. The result was a more competitive product price and higher overall quality.

Customer:
TRW Automotive

Part Name/Number:
Base Connector/C-0472

Molding Information:
• Wellamid
• 30% glass-filled nylon

Insert Information:
Terminal pin

PCB Connector for Power Window Switch

Complexity is no obstacle with insert molding. Insert molding simplified production of this small, complex part which includes a slot and a voided area. A single die blanks and forms the insert, producing four tin-plated brass contacts at once.

Customer:
TRW Automotive Electronics Group

Part Name/Number:
KJ Window Switch Connector/C-0517

Molding Information:
Wellman MR410-22M-M Natural mineral filled nylon

Insert Information:
Post-plated tin over brass

IBM Tape Drive

Insert molding replaces machined-and-assembled process for a 90% savings. This component was originally a machined and assembled metal part, costing in excess of $75.00 each. By contrast, our insert molded design yielded a part that ran in production quantities at about 10% of that cost.

Customer:
IBM

Part Name/Number:
IBM Complete Assembly/C-0513

Molding Information:
• Vectra E13-1 - 30% glass-filled liquid crystal polymer (LCP)

Insert Information:
• 1 Nickel plated CRS Cup
• Two aluminum threaded inserts
• Two bronze bushings

Zip Drive Carriage Assembly

Highly complex zip drive component is produced using insert molding. Insert molding met the challenge for efficiently producing this part with ultra-precise tolerances and intricate subcomponents. The subcomponents include a rectangular voice coil, two stainless steel stampings, and two miniature sapphire bearings.

Insert molding allows the subcomponents to be combined during production, rather than requiring expensive assembly. To check the tolerances after molding, the component is loaded into a fully automated dimensional check and part tuning system, located on-site. This system measures the parallelism of the stampings and, if necessary, automatically moves the stampings into position to meet ± 0.001" tolerance guidelines.

Customer:
Iomega

Part Name/Number:
Carriage Assembly Sqat/C-0494

Molding Information:
• Vectra E130-1 Natural
• 30% Glass-filled LCP

Insert Information:
• Carriage Arm, .010 thick stainless steel 1/2 Hard Temper
• Coil Assembly, Totoku 0.114 2-SF
• Round Sapphire or Zirconia Bearing
• Slotted Sapphire or Zirconia Bearing

Dishwasher Filter Top

Superior dimensional stability and cost efficiency achieved with insert molding. Insert molding offers ideal dimensional stability for filter components that must retain their shape over repeated washings, like this Maytag filter top for a dishwasher pump cover. Because the filter media is molded securely into position, it resists deformity or detachment of the filter material.

Using prototypes, Microplastics engineers developed a unique, cost-effective process to locate and adhere the filter media in place. The now proven product is manufactured in two identical molding systems that run nearly 24 hours a day, five days a week.

Customer:
Maytag

Part Name/Number:
Maytag Filter Top

Molding Information:
• Polyfill GF PP 10

Insert Information:
• Polyester screen
• .005" Thickness
• Dimensions: 1.523" x 5.1", arc shaped

Airbag Sensor Housing for GM

Unique Microplastics "Retracting Core" technology cuts production costs. Using internally-built retracting core technology, Microplastics was able to produce a sealed housing for this side-impact airbag sensor, while eliminating the back cover that was originally designed in by the Delphi Delco Electronics team. This unusual insert molding concept resulted in a more cost-effective production, which translated into a more competitive product.

To produce the housing, Microplastics first built a tool, internally funded, to develop the retracting core technology. With proven success, we were awarded the prototype and production program with Delphi Delco. Microplastics is now producing the next generation of the original product.

Customer:
Delco Electronics Singapore

Part Name/Number:
Side impact module/C-0471

Molding Information:
• Celanex 3300-D
• 30% glass-filled PBT

Insert Information:
• Threaded bushing
• Leadframe copper
• Tin plated aluminum clad

Power Steering Housing

Insert molded design cuts cost by more than 60%. Before its redesign as an insert molded part, this housing for an electrohydraulic power steering system was originally designed at a cost of over $11.00 each. Microplastics insert molding engineers worked closely with Delphi engineers to improve the design, reducing the cost of the product to less than $3.00 each.

Customer:
Delphi Delco Electronics

Part Name/Number:
Electro-Hydraulic PS/C-0475

Molding Information:
Zytel 70G33HS1L BK031 Black (33% Glass-filled Nylon

Insert Information:
• Leadframe C102 Cu HH, AI Inlay
• .002/.004" thick Tin Plate

Promotional Flashlight

Insert molding cuts production costs in half. This flashlight was produced at less than half the customer’s original assembled cost using insert molding to reduce assembly labor. At the same time, inserts are so securely molded into place that the end product is more reliable.

Customer:
Pressalite Corporation

Part Name/Number:
Pressalite/C-0506

Molding Information:
• Polypropylene Homopolymer
• 0.009" thick
• 1/2 Hard Brass,
• 20% Talc MDK 372 white

Insert Information:
• I-0506-1 Leadframe Contact
• I-0506-2 Bulb Clip

Dome Lamp for GM

Single part replaces 12-component assembly. Insert molding allowed this part to be produced as a single component, replacing a complicated assembly process that combined 12 individual pieces. This significantly reduced the unit cost and eliminated numerous problems including the possibility of failure during assembly from crossed wire termination, poor quality termination in four locations, wires being yanked loose into the vehicle, vibration, poorly swaged studs, a loose connector shroud, terminals backing out during insertion of the connector, and misalignment of the terminals to the shroud.

Customer:
Christiana Industries

Part Name/Number:
Base Plate/C-0425-1, C-0425-2, C-0425-3

Molding Information:
• Wellamaid MR41022H-N Natural 6/6 Nylon

Insert Information:
• I-0425-1 Terminal Insert (pair)
• .015" Thick 304 Stainless Steel, Quarter Hard Temper

Map Lamp for Automotive Lighting

Making a complicated part simple. Insert molding allowed a single, solid piece of plastic with multiple dimensions and cutouts to hold lighting fixtures in this circuit plate for an automotive interior lighting application. Microplastics developed a solid model from the customer's original design, allowing the product to go straight to production tooling without prototyping.

Customer:
Lear Seating/Arkay Industries

Part Name/Number:
Console circuit plate/ C-0496

Molding Information:
• Wellamid Natural
• 40% mineral-filled nylon

Insert Information:
• Leadframe
• Heat Shield
• Bulb Clip

Telephone Switching System Assembly

Cost and accuracy challenges met with insert molding. This delicate rotary four-pole switching assembly presented a manufacturing challenge because of its 12 mm diameter x 9 mm high size, and because its gold and silver plating on Berrylium copper required a minimization of excess material to save costs. Careful tooling and advanced insert molding techniques helped meet the requirements while also meeting the accuracy demands of placing 200 dimples per sheet.

Customer:
Otto Engineering

Part Name/Number:
U2 Rotary Switch/ C-0485

Molding Information:
Hoest Cleanese Cleanex 3300-D

Insert Information:
• Berrylium copper stamped inserts
• Gold and silver plating

Insulator for Automotive Door Lock Switch

Insert molding allows component improvement. After some initial difficulties interpreting this customer's prints which used Japanese rather than U.S. tolerancing methods, our engineering and tooling groups built tooling to produce a part that improved upon the initial design, and exceeded the customer's expectations. Today, we are regarded as their #1 insert molder.

Customer:
Tokai Rika

Part Name/Number:
Insulator CP/C-0454

Molding Information:
• Celanex 3300 Natural
• 30% glass-filled PBT

Insert Information:
.032" thick copper terminal insert, 1/2 hard tempered