JinYi Moulds is professional in mass production of front bumper cross beam brackets for passenger cars and trucks. This is a crucial link of impact force transmission. The main functional characteristics are: high precision for assembly; strong impact toughness for withstanding impact; and long-life resistance to fatigue under engine compartment conditions with temperatures varying from -40°C to 120°C. Based on the experience in mass production for famous international car manufacturers such as BMW, we at JinYi Moulds have incorporated CAE simulation design, precision mold processing, and automatic production to meet the performance.
Meanwhile, our engineering abilities are not limited to auto front ends. In the development of marine instrument panel molds, we actually utilize the knowledge of material and surface treatment technology built up in dealing with high-salt spray and high UV conditions in reverse-engineered form in optimizing the process of corrosion-resistant coating on the bracket. On the other hand, research on failure modes in assembly, specifically on rearview mirror separation, was thoroughly performed in our company. Improvement on the design notion of vibration durability and structures of connection points in such failure modes was applied in designing bumper brackets and body mounting points.
Performance Design:
In our work before mold design, we performed an entire analysis chain with the help of Computer-Aided Engineering.
Moldflow Analysis:
Improved the gating and cooling design for proper filling of PA-GF material in long-runners, maintaining shrinkage values between 0.2%-0.4%, and a tolerance of ±0.1mm on the mounting hole locations.
Structural Analysis:
Simulated stress distribution on components under static, low-speed impact, and vibration loading, and conducted topology optimization to minimize weight with respect to strength. The simulation results were used to design the mold cooling system to minimize internal stresses in the mold during molding.
Mold Manufacturing:
The mold is produced with pre-hardened high quality mold steel. The surface of the crucial moving parts is nitrided for improved wear resistance. Five-axis high speed milling and accurate EDM machining were employed. The tolerance for the surface contour on the mold is limited to a value of 0.02mm. The cooling system for the mold employs conformal 3D printed water channels that boost cooling efficiency by a value of 25%.
Automated Production Process:
Our injection workshop is equipped with a large injection mold machine with a clamping force over 850 tons, using closed-loop servo control and a six-axis robot for automatic material transportation, online visual inspection for material deficiency, flash inspection, and stacking. The highly efficient production line is up to our automated production standard for the manufacture of high-load structural parts for automotive scissor lifts, automotive equipment, with quality ensured over millions of batches.
Validation and Quality Assurance
It also adheres to IATF 16949 standards with a stringent validation process from materials to assembly.
Mold & Process Validation:
The molds undergo T0 to T2 trial molding, and reports of dimension measurement from a coordinate measuring machine, tensile test reports, impact test reports of the mechanical properties of the materials, and assembly matching samples are provided.
Product Performance Validation:
The mass-produced parts are subject to 3D-coordinate measurement, and the samples for the environment durability test are sampled periodically and include the following:
High and Low-Temperature Cycle tests from -40°C to 120°C
Vibration tests according to the standards of SAE J2380
Salt Spray Corrosion tests for a period of at least 720 hours
Load and Road Testing:
The company assists customers with the process of assembling vehicle verification as well as on-road durability tests to validate component function.
JinYi Mould can provide services including concept design, CAE simulation, mold making, and delivery. In addition, due to our modular mold design, we can quickly adapt to any modification of the bracket needed for different models. Our production line also combines an integrated MES system to monitor data online and provide traceability. If you are working on a next-gen vehicle platform front structure system and are looking to collaborate with a company with rich experience in designing heavy-load structures, precision molds, and quality management for mass production at a level found in the automotive industry, we can assist you with this.
About Us
Jinyi Mold was established in 1998 and is headquartered in Dongguan, Guangdong. Our professional team provides injection mold and die-casting mold services, providing you support in every aspect from design, manufacturing to final assembly.
Production equipment:
dozens of CNC machining centers (gantry & 5-axis), injection molding machines (80-1600 tons), EDM machines, automation equipment, etc.
Scope of services:
Establish solid partnerships with Europe, Australia and Asia to carry out international export business.
Company production capacity: A 13,000㎡ production base in Maoming (built in 2022), backing an annual turnover surpassing 150 million RMB.
Honors and qualifications:
Possess High-Tech Enterprise Certification, ISO9001:2015 Quality management system certification.
Logistics and freight:
Logistics follows international transportation standards, and packaging is packed in reinforced wooden boxes, filled with PE foam and wrapped in moisture-proof bags.
Marketing: Selina Chan
WhatsApp:+8618969686504
Email:selina@jy-mould.com
Contact us to discuss how we can support your project needs
Please know that when you choose Jinyi Mold, we are not only a supplier, but also a Chinese manufacturing partner with 25 years of experience in mold design, manufacturing, and assembly.
