Injection Molding for Emergency Trunk Release Handle: Phosphorescent Polypropylene, Glows in the Dark, Silkscreen Graphics, Flame Treatment, Applied Velcro, Secondary Operations, ACM

Injection Molding for Automotive Wiring Harness

This wiring harness we molded for Ford required that we make the three corresponding covers that go with them. At the request of the customer, we custom-built a machine to perform a secondary operation, inserting limiters into the molded part. It was an error-proofing process to ensure that all parts had the limiters in place and that they were flush to the surface.

Injection Molded Wiring Harness

• Parts were injection molded using a hot runner / hot manifold system that was gated in three places to produce no runner
   
• Secondary insert operation done at the injection molding machine:
   
  • Three limiters were inserted into the wiring harness, two oval and one round
     
  • We purchased limiters,  made of a pressed metal, from an outside vendor in Michigan
     
  • Limiters all had to be oriented properly and inserted while the molded part was still warm

To do this, we custom-built a machine to orient the limiters in their correct positions, sense that they were in place, press them to the correct depth, and make sure the correct number of limiters were inserted when assembly is done.  

	This machine, custom-built at the request of the customer, was designed to error-proof a secondary insertion operation. Click for larger images.

• The machine is run pneumatically
   
• In between shots, the operator places the limiters into the machine
   
• When the plastic part is ejected from the mold the machine takes the part and slides it into position
   
• The pneumatics all fire and push the limiters into position
   
• An electronic eye sensor is in place at all three positions to:
   
  • Electronically verify that the limiters are in place, and
     
  • They are inserted to the proper depth
     
  • If not, an alarm goes off to alert the setup operator or maintenance crew that there is a problem

Advanced Injection Mold Design & Engineering: BMJ's Advantage

Our affiliate, BMJ Mold and Engineering, has been producing high-quality molds for four decades. BMJ's reputation is built on a long history of on-time delivery and quick turnaround time for mold build. All BMJ-built molds are guaranteed to perform to customer specifications.

For more information, see the BMJ webpage: Mold Building.

For a quote or more information about how we can help your project, call 765-457-8225, or send us an email, or submit this short form:

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