European EV Tier 1 Supplier

Battery pack cooling air duct blow mold project (PA6+GF material)

PAIN POINTS

EV battery pack cooling ducts have complex 3D curved surfaces. The old mold's unstable parison control caused wall thickness deviation of ±1.0mm, interfering with battery modules during assembly. Uneven cooling caused elliptical deformation at duct interfaces, preventing tight seal ring fit and creating coolant leakage risk.

MOTEK SOLUTION

• Used 7075 aviation aluminum forged cavities with 3D parison program control, controlling wall thickness deviation within ±0.4mm.
• Designed dedicated cooling inserts at duct interfaces, ensuring roundness ≤0.3mm for tight seal ring fit.
• Achieved 28% weight reduction through structural optimization and material thinning, supporting vehicle lightweighting goals.

"motek's air duct mold improved our assembly first-pass rate from 85% to 99.5%, helping us achieve our vehicle lightweighting target."

North American Commercial Vehicle Parts Supplier

200L multi-layer co-extruded diesel fuel tank blow mold project (with baffle + fuel level sensor port)

PAIN POINTS

Multi-layer co-extruded fuel tanks must withstand fuel corrosion and vibration fatigue. The old mold's insufficient interlayer weld strength caused delamination during ECE R34 vibration tests. Baffle weld strength was insufficient, causing rattling on rough roads. Uneven blow-molding shrinkage caused dimensional deviation at the fuel level sensor port, making sensor installation difficult.

MOTEK SOLUTION

• Optimized parison temperature and mold closing sequence, improving interlayer weld strength by 35% and passing ECE R34 certification.
• Designed dedicated baffle positioning inserts and weld reinforcement structure, eliminating rattling on rough roads.
• Used dedicated cooling inserts at sensor port, controlling dimensional accuracy within ±0.2mm for smooth sensor installation.

"motek's fuel tank mold helped our product pass ECE R34 certification on the first try. Our clients are very satisfied with interlayer strength and assembly precision."