At FCE, our commitment to injection molding excellence is reflected in every project we undertake. The development of the Mercedes parking gear lever plate serves as a prime example of our engineering expertise and precise project management.
Product Requirements and Challenges
The Mercedes parking gear lever plate is a complex double-shot injection molded component that combines intricate aesthetics with stringent performance standards. The first shot consists of white polycarbonate (PC), requiring precision to maintain the logo’s shape during the second injection shot, which involves black PC/ABS (polycarbonate/acrylonitrile-butadiene-styrene) material. Achieving a secure bond between these materials under high temperatures while preserving the white logo’s shape, gloss, and clarity against the black background presented a unique challenge.
Beyond aesthetic precision, the product also needed to meet high durability and functionality standards, reinforcing its structural integrity and resilience over time.
Formation of a Specialized Technical Team
To meet these stringent injection molding requirements, we assembled a dedicated team with deep expertise in double-shot molding. The team began with in-depth technical discussions, learning from previous projects and examining every detail—focusing on product design, mold structure, and material compatibility.
Through a thorough PFMEA (Process Failure Mode and Effects Analysis), we identified potential risk factors and formulated precise risk management strategies. During the DFM (Design for Manufacture) phase, the team carefully refined mold structure, venting methods, and runner designs, all of which were reviewed and approved in partnership with the client.
Collaborative Design Optimization
Throughout development, FCE maintained close collaboration with the client, working through multiple rounds of design optimization. Together, we reviewed and refined each aspect of the injection molding process, ensuring not only that the design met performance standards but also that manufacturing and cost efficiencies were maximized.
This high level of collaboration and transparent feedback provided confidence to the client and enabled seamless coordination across different manufacturing stages, earning our team high praise for its professionalism and proactive approach.
Scientific Management and Steady Progress
FCE applied rigorous project management to keep the development on track. Regular meetings with the client provided real-time progress updates, enabling us to address any concerns immediately. This ongoing interaction solidified a strong working relationship and fostered mutual trust, keeping the project aligned with our shared goals.
The client’s consistent feedback and recognition of our efforts highlighted our team’s technical acumen, professionalism, and efficient execution.
Mold Trials and Outstanding Final Results
During the mold trial phase, every process detail was carefully tested to achieve a flawless outcome. After the initial trial, we made minor adjustments, and the second trial yielded exceptional results. The final product showcased perfect appearance, translucency, logo contours, and gloss, with the client expressing tremendous satisfaction at the precision and craftsmanship achieved.
Continued Collaboration and Dedication to Excellence
Our work with Mercedes represents a commitment to quality that extends beyond individual projects. Mercedes upholds rigorous quality expectations for its suppliers, and each generation of products challenges us to meet ever-higher technical standards. At FCE, this pursuit of excellence through advanced injection molding aligns with our core mission to deliver innovation and quality.
FCE Injection Molding Services
FCE offers industry-leading injection molding services, from precision injection molding to complex double-shot processes. With a dedication to innovation and client satisfaction, we help our partners achieve top-tier results, reinforcing FCE as a trusted choice for advanced injection molding solutions.
Post time: Nov-08-2024