Manufacturing example: Cable holder tool

Fertigungsbeispiel: Kabelhalterung

Success through combined technologies

ARaymond is one of the world's leading manufacturers of advanced fastening and assembly systems, especially for the automotive industry. Many of these fasteners have to be extensively tested to meet the stringent requirements of vehicle production. For this purpose, near-series components made from the original material are required.

The cable holder in question is a test series with a batch size of 3,000 pieces, which was produced by FIT using a combination of additive manufacturing and conventional technology. Metal 3D printing was used for the injection mold. The small batch production is realized via injection molding.


Additive Fertigung des Spritzgusswerkzeugs

Additive manufacturing of the injection mold

The starting point for the mold design was the 2D drawing as well as the 3D data set of the cable holder, which were provided to the mold experts at FIT by ARaymond. The feasibility check yielded a positive result, so that the CAD design of the injection mold could be started directly. After completion of the design, the mold was coordinated with ARaymond in terms of mold separation, sprue concept and ejector positions and final approval by the customer was given.

The mold was produced by laser melting (LM or PBF-LB/M) from maraging steel (1.2709 or M1) within 3 working days. This was followed by the finishing steps of milling, polishing, eroding and touching, so that the mold was available for injection molding after 7 working days.


Spritzgussfertigung der Kabelhalterung

Injection molding production of the cable holder

Before the production of the small series started, a sampling was carried out at the request of ARaymond, i.e. a production of 100 test parts. In the quality labs of FIT, the properties of the test parts were determined by:

  • a tactile measurement as well as
  • a false color adjustment by micro-CT scan

After approval of the test parts by ARaymond, 3,000 cable holders from PA 6 GF15were produced using injection molding. FIT has various injection molding machines with a clamping force of up to 150 t.

The small-batch production was monitored during production in accordance with the quality specifications so that the near-series properties of the cable supports were fully met at all times.

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The special process requirements

The components were used by ARaymond for functional tests and design verification as part of the product development process. The quality of the cable holders allows conclusions to be drawn for the optimization of the design and the final series tool. The faster this iteration takes place, the sooner the product can be launched on the market.

The benefits of rapid tooling for ARaymond:

  • 40% cost savings by 3D printing the tool.
  • 50% time savings in delivering the parts for functional testing.

Would you also like to benefit from low tooling costs and fast delivery? Then contact us. Together we will find a solution.


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Steps to your injection molding tool and parts

Our services

Content

Results

Feasibility check
We discuss your individual initial situation and objectives with you. On this basis, we develop a recommendation for you for the production of the tool and the series parts.
You will receive concrete recommendations for necessary adjustments to your design as well as information on manufacturing costs and times.
Tool design
Based on the component's CAD data, our experts design an injection molding tool that can be additively manufactured quickly and cost-effectively.
Based on the component's CAD data, our experts design an injection molding tool that can be additively manufactured quickly and cost-effectively.
Tool production
We manufacture the injection mold from tool steel by laser melting (LM or PBF-LB/M) and mill, polish, erode and touch the mold.
The mold is available and can be used immediately in our own injection molding facilities.
Sampling
If required, we can carry out a test run of conventional injection molding production with appropriate quality assurance.
Test parts and the associated quality certificates are available to you for approval.
Injection molding pf parts
After approval of the sample parts, the actual injection molding of the desired batch size takes place.
The desired edition is made in the original material, packed and shipped to you.
Quality assurance during the process
If required, we carry out a quality inspection during production according to your specifications.
You are handed out the corresponding quality certificates.

Technical facts about the cable holder tool

FIT solution:Rapid tooling
Scope of services:Tool design
Additive manufacturing and post-processing
Sampling
Injection molding of small batch series
QA documentation (material test certificates, material
certificates, measurement reports)
Packaging and shipping
Delivery time:15 working days
Par dimensions:95 x 40 x 15 mm
Part weight:12 g
Lot size:3,000 pc
Material (tool):Maraging steel (1.2709 resp. M1)
Technology (tool):Laser melting (LM resp. PBF-LB/M)
Material (parts): :PA 6 GF15
Technology (parts):Injection molding
Quality control:Tactile 3D coordinate measurement
Micro ct scan (false color)
Certificate:ISO 9001

Learn more here!


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Robert Lengenfelder

Your contact person

Robert Lengenfelder
Technical expert tool making, injection molding

+49 9492 9429 62

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