FCE’s Excellence in Injection Molding: A Key Supplier for Tesla’s New Model 3 Cup Holder Handle
FCE has become a trusted partner in the production of a critical automotive part for the new Tesla Model 3— the cup holder handle, an essential exterior component that requires the highest standards in both appearance and functionality. As an exterior part, the product demands flawless aesthetics, with zero defects allowed on the surface. The manufacturing process involves a combination of injection molding and spray painting, making it one of FCE’s most significant projects.
Stringent Requirements for Injection Molding
The cup holder handle is entirely composed of visible surfaces, which must be free from any defects such as shrink marks, weld lines, or flash at the parting line. Additionally, the spray-painted finish must achieve a high-quality, visually appealing result. Given the part's considerable length, it is critical that no warping occurs during production, and the assembly holes must meet precise positional tolerances. To achieve these exacting requirements, precision mold design and a high-accuracy injection molding process are crucial.
Collaborative Feasibility Analysis and Advanced Simulation
From the outset, FCE worked closely with the client to conduct an extensive feasibility analysis. After developing a Design for Manufacturing (DFM) plan, the proposal was submitted and approved by Tesla’s engineering team. FCE then performed Mold Flow Analysis, simulating the product’s material flow and injection parameters to ensure optimal production results. Following a successful simulation, both FCE and Tesla agreed to proceed with the mold manufacturing.
FCE utilized high-precision CNC machines and EDM equipment to create the mold, ensuring that critical tolerances were met within +/-0.005mm. For components with stringent requirements, FCE adopted a single-pass precision machining process, ensuring uniformity in the product’s final appearance.
High-Precision Injection Molding Process
During the injection molding phase, FCE employed Sumitomo injection molding machines, renowned for their precision and stability. These machines enabled consistent production with minimal variability between cycles. FCE conducted trials with various process parameters, ultimately selecting the most suitable configuration to optimize both the product's appearance and dimensional accuracy. Once the ideal parameters were established, they were standardized for all subsequent production runs, ensuring batch-to-batch consistency.
Rigorous Quality Control Measures
Quality control is a vital aspect of FCE’s production process. FCE custom-designed inspection fixtures that replicate the product's actual installation environment. These fixtures are used to verify key dimensions during production and before shipment, ensuring the product's straightness and installation accuracy. Additionally, FCE records all critical data, including raw material batch numbers, machine parameters, inspection results, and shipping details. These records are retained for more than five years, providing full traceability and allowing FCE to address any potential issues promptly.
Flawless Production and Zero Defects
FCE has been supplying this critical automotive part to Tesla for over a year, with a production volume exceeding 500,000 units. Remarkably, FCE has received zero quality complaints from Tesla and has encountered no market-related issues. FCE’s superior production capabilities and robust quality control processes have earned the trust and long-term partnership of Tesla, making FCE a key supplier for their Model 3 production.
By leveraging advanced injection molding techniques, stringent quality controls, and cutting-edge machinery, FCE continues to deliver high-quality automotive parts that meet the demanding standards of the industry. This successful collaboration with Tesla highlights FCE’s commitment to excellence and positions the company as a leader in precision injection molding for the automotive sector.
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