Project: Car Seat Adjustment Slide Rail Bracket for Automotive
Service: Plastic Injection Molding
Mold Material: P20 tool steel
Part Material: PP-TD20
Quantity: 200 pcs
Mold Life: 5000 shots
Lead Time: 20 days
About The Product
The customer is recommended by a colleague of the overseas company, there is an urgent project about making the accessories of the car seat sliding system, including the car seat adjustment slide rail bracket, gear height adjustment bracket and angle adjuster, he is looking for a plastic injection molding company with experience in rapid mold to do this job, to ensure he could get the good samples in a very short lead time, so he could verify the design works for the system. Our customer is one of the largest family-owned automotive supplier. Who is specializing in the synthesis of mechanical, electrical, electronic and sensor systems. Every second new vehicle is equipped with at least one of their product worldwide. Danke Mold team were excited to support customer and finally get the parts come to the market earlier than expected.
Design For Manufacturing Review Recommendations
Once our Project Engineers received the product design for the Rail bracket and associated parts, we submit a design for manufacturing review.
We comment that some of the areas need slight adjustments to make it manufacturable. Main challenges are considered in the DFM review included the following:
Parting Line 
The parting line shows the separation between the core and cavity of the mold.
To ensure the final part works as expected for customer,
we need to consider placing the parting line correctly,
without affect the functional dimensions,
but allowing good mold structure and parts to be released from the mold.
Injection System 
The parting line shows the separation between the core and cavity of the mold.
Balance of the material flowing, ensure to fulfill the part and minimize the experience warp.
Draft Angle
We suggest to apply a draft angle of 0.5-1°on the outside surfaces of the part, 
appropriated mold draft would allow the parts
to be released from the mold and avoid scratches/sticking issue.
Wall Thickness
The parting line shows the separation between the core and cavity of the mold. To ensure the final part works as expected for customer, we need to consider placing the parting line correctly, without affect the functional dimensions, but allowing good mold structure and parts to be released from the mold.
Choosing The Best Material for the Mold
Reviewing the part design and the customer’s need for this parts, our engineering team still recommended to use S50C steel for this tool(same as quoted), although we could use aluminum to make the core and cavity, using S50C for this tool would be better for below reasons:
1,200 parts are needed
2,Mold life required is within 1000 shots
3,Internal structural part and normal C3/C3 finish required
4,This is to verify design and customer might possible need to change the design, S50C would be feasible for EC instead of aluminum
Mold Design
Same as we quoted for the molds, we design to make prototype molds for these parts, make core/cavity in solid for the Rail bracket part and MUD unit for the smaller parts with shared mold based. Sliders and lifters are still available even though we use the MUD mold bases.
