PANBALAN SANTHOSHAM — NPD ENGINEER

Challenge: Design a production-ready single-cavity injection mould for an automotive High Hose A component while ensuring dimensional accuracy, efficient cooling, smooth ejection, and manufacturability. The mould needed to produce high-quality parts consistently while minimizing potential manufacturing defects.

Process: Analyzed the product geometry and manufacturability requirements. Defined the parting line and mould opening direction. Designed core and cavity inserts based on product geometry. Developed the cooling system to optimize heat dissipation. Designed the ejection mechanism for reliable part removal. Created the complete mould assembly and manufacturing drawings. Reviewed and validated the design before manufacturing.

Solution: Developed a single-cavity injection mould featuring optimized core-cavity construction, cooling channels, and an efficient ejection system. The complete mould assembly was modeled in CAD and prepared for manufacturing, ensuring reliable production performance and part quality.

Outcome: Successfully designed and manufactured a production-ready injection mould. Achieved accurate replication of the High Hose A component. Improved understanding of mould design, cooling optimization, and ejection systems. Gained practical experience in tool manufacturing and production validation. Enhanced skills in CAD modeling, DFM, and automotive component development.