Fuel tank level sensor (TN sensor) for oil return, filter, automotive fuel tank sensor, resistive fuel level sensor (0-190Ω)
FEATURES
The "Hard Power" Foundation — Building Customer Trust Through Equipment Excellence
1.1 Mold Manufacturing Equipment
Ansix Tech's mold workshop is equipped with world-class precision machining centers that directly translate into measurable customer value:
Five-Axis High-Speed Machining Centers (Mikron, Makino): Capable of machining complex curved surfaces with 0.002mm precision. For TN sensor housings, this means:
Customer value: Seamless, burr-free parting lines eliminate secondary deburring operations, saving 5-8% in post-processing costs per part.
Risk reduction: Precision-matched mold halves prevent flash, reducing scrap rates and ensuring consistent sensor housing sealing performance.
Slow-Wire EDM (Electrical Discharge Machining): Enables 0.03mm fine holes and narrow slots.
Customer value: Enables intricate sensor component geometries without thin-wall deformation—critical for the float guide tubes and connector pin cavities in TN sensors.
Risk reduction: Prevents wall collapse during demolding, ensuring dimensional integrity of thin-wall sensor housings.
EDM and Electrode Machining Centers: In-house electrode production and EDM capabilities mean mold repairs and modifications are completed without outsourcing.
Customer value: 24-hour turnaround for routine repairs and insert replacements—minimizing production downtime.
Cost savings: Eliminates third-party markup and logistics delays.
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Mold Description
Product Materials:
SUS304+NBR FOAM
Mold Material:
S136ESR
Number of Cavities:
16
Glue Feeding Method:
Hot runner
Cooling Method:
Water cooling
Molding Cycle
42.5s
- The mold manufacturing process and product material selection
Injection Molding Machine Fleet
Ansix Tech operates 260 injection molding machines across four facilities, featuring brands including Fanuc, Sumitomo, Toshiba, Nissei, Engel, and Arburg (the latter primarily for LSR two-component molding), along with domestic brands Haitian and Victor. The clamping force range spans 30 tons to 2,800 tons.
All-servo electric drives deliver repetitive precision of ±0.1%:
Customer value: Every shot is identical to the last—batch-to-batch consistency eliminates the need for customers to re-qualify incoming parts.
Cost savings: Stable processes mean fewer adjustments, less scrap, and predictable production schedules.
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Inspection and Metrology Equipment
Coordinate Measuring Machines (CMM) and Optical Imaging Systems:
Customer value: Every mold shipped from Ansix Tech undergoes a full dimensional report comparison, with critical dimensions held to CPK ≥ 1.33.
Risk reduction: Statistical process control data provides customers with documented evidence of process capability—essential for IATF16949 compliance and PPAP submissions.
Steel Material Certification & Heat Treatment Profiles: Every mold ships with full material certifications and heat treatment records.
Customer value: Full traceability from raw material to finished part—customers can verify exact material composition and processing history.
Risk reduction: Eliminates the risk of substandard steel causing premature mold failure.
Part II: Mold Manufacturing Core Competencies — Speaking the Language of Customer Value
2.1 Mold Life and Durability
Dimension Technical Specification Customer Value Translation
Mold Steel Selection Mold base: P20; Core/Cavity: S136 (HRC 48-52), 2344, 2343, 8407, SKD11/61, DC53, M340, 4Cr13, 9Cr18, NAK80, H13 Each steel grade is selected based on specific application requirements—corrosion resistance for fuel-exposed components, wear resistance for glass-filled materials
Mold Life Guarantee 500,000 shots for glass-fiber reinforced materials; 1,000,000 shots for standard plastics Predictable tooling amortization—customers can accurately forecast per-part tooling costs over the product lifecycle
Achievable Tolerances Standard structural parts: ±0.05mm; Precision gears/medical components: ±0.005mm TN sensor housings achieve the tight tolerances required for float mechanism clearance and connector pin alignment
2.2 Mold Types and Capabilities
Ansix Tech's mold manufacturing portfolio includes:
Hot Runner Systems: Reduce material waste and cycle time.
Customer value: For high-volume TN sensor production, material savings alone can reduce per-part cost by 3-5%.
Stack Molds: Double production efficiency in the same machine footprint.
Customer value: Doubles output without additional capital investment in new molding machines.
Two-Shot / Multi-Material Molds: Enables overmolding of different materials in a single cycle.
Customer value: Eliminates secondary assembly operations—critical for sensor housings requiring both rigid structural sections and flexible sealing elements.
High-Gloss Molds (Ra < 0.05μm): Suitable for transparent or optical-grade components.
Customer value: Transparent sensor windows or indicator lenses require no secondary polishing.
Insert Molding Capability: Precision placement of metal inserts (terminals, pins, bushings) into the mold cavity before injection.
Customer value: For TN sensors requiring integrated electrical terminals, insert molding eliminates separate assembly steps, reducing labor costs and improving reliability.
Risk reduction: Proper insert design (knurling, grooves, holes for mechanical locking) prevents insert pull-out and ensures electrical continuity.
2.3 Gate and Runner System Design
Through Moldflow and Moldex3D simulation, Ansix Tech optimizes gate location and runner systems before steel is cut:
Customer value: Predicts and eliminates weld lines, gas traps, and short shots before production begins—preventing costly mold rework.
Cost savings: Optimized filling ensures balanced cavity filling, reducing material waste and cycle time.
Risk reduction: Proper gate placement prevents visible witness marks on cosmetic surfaces and ensures structural integrity at critical sealing areas.
2.4 Cooling System Design
Ansix Tech employs 3D-printed conformal cooling channels that follow part contours:
Customer value: Uniform cooling reduces warpage and dimensional variation—critical for TN sensor housings that must maintain precise float guide clearances.
Cycle time reduction: Cooling typically accounts for over 70% of the injection molding cycle. Conformal cooling can reduce cycle times by up to 28%.
2.5 Delivery Standards
Mold Complexity Standard Lead Time Expedited Option
Simple molds 10 days —
Medium complexity 25-45 days 20 days (with parallel validation)
Complex/high-cavity 45-60 days Available upon request
Expedited delivery commitment: Even under accelerated timelines, Ansix Tech does not skip validation steps. The DFM, moldflow analysis, and trial sampling phases remain intact.
Part III: Injection Molding Process Control — Eliminating Quality Anxiety
3.1 Process Standardization and Monitoring
MES-Connected Machine Network: All molding parameters (temperature, pressure, speed, timing) are locked in the MES system:
Customer value: Only authorized engineers can adjust parameters—eliminating unauthorized operator changes that cause quality drift.
Risk reduction: Every batch undergoes first-article and last-article inspection, ensuring process stability across entire production runs.
3.2 Dimensional Stability Control
Zone Temperature Control with Mold Temperature Controllers: Core and cavity temperature differentials maintained within 2°C:
Customer value: Minimizes warpage and shrinkage variation—TN sensor housings maintain critical dimensions such as float guide tube diameter and mounting flange flatness.
Data point: For similar automotive sensor components, key hole-to-hole spacing variation ≤ 0.02mm across three consecutive production batches within one week.
Ultrasonic Wall Thickness Sensors: Real-time feedback on wall thickness fluctuations with automatic compensation of holding pressure:
Customer value: Eliminates dimensional drift over long production runs—every part meets specification.
Cost savings: Reduces scrap and rework, improving first-pass yield.
3.3 Appearance Quality Standards
Requirement Achievable Specification Customer Value
Transparent parts No bubbles, no flow marks Clear windows for optical sensors or indicators
Platable parts No gas marks Consistent adhesion for plated or coated surfaces
High-gloss parts Surface roughness Ra ≤ 0.2μm Ready for painting/decorating without priming
Printed/coated parts Registration accuracy ±0.1mm with compensation Consistent graphic placement, reduced rejection
3.4 Special Material Processing Capabilities
Ansix Tech has extensive production experience with engineering thermoplastics including:
PC/ABS blends (e.g., Makrolon® grades): Impact strength, heat resistance, and fuel/oil compatibility—ideal for TN sensor housings exposed to diesel and temperature extremes.
PPS (Polyphenylene Sulfide) + 40% GF: Superior heat resistance and chemical resistance—suitable for under-hood sensor applications.
PBT (Polybutylene Terephthalate): Excellent dimensional stability and electrical properties—commonly used for sensor connector housings.
PA6/PA66 + GF30 (Nylon with 30% glass fiber): High strength and thermal stability for structural sensor components.
PEI (Polyetherimide), PEEK, LCP (Liquid Crystal Polymer): High-performance materials for extreme environments.
PTFE/PFA: Chemical resistance for fuel-exposed components.
LSR (Liquid Silicone Rubber): For overmolded seals and gaskets.
Flame Retardant Grades (UL94 V-0): For applications requiring fire safety compliance.
UV Stability: Tested to 3,000 hours UV exposure without discoloration—ensuring sensor housings maintain appearance and structural integrity in outdoor applications.
Part IV: Full-Process Service — Reducing Customer Management Costs
4.1 Early Intervention (DFM Reports)
Before any steel is cut, Ansix Tech provides a comprehensive Design for Manufacturability (DFM) analysis:
Customer value: Identifies and resolves manufacturability issues at the design stage—when changes cost the least.
Specific deliverables: Draft angle recommendations, wall thickness optimization, gate location, ejector pin mark location allowances.
Cost impact: Up to 70% of final component manufacturing cost is locked in during the initial design phase.
4.2 Trial Molding and Sampling
T0 to T3 Trial Samples: Each trial iteration comes with a detailed improvement report:
Customer value: Customers receive functional samples at each stage, providing visibility into the development process.
Flexibility: Quick-change inserts allow validation of different design variations without rebuilding the entire mold.
4.3 Low-Volume Pilot Production
100-500 shot pilot runs before full production release:
Customer value: Statistical validation of yield and CPK ensures process stability before committing to high-volume production.
Risk reduction: Identifies and resolves any remaining process issues at minimal cost and material usage.
4.4 Maintenance and Spare Parts
Spare Parts Kit: Ejector pins, core inserts, and other wear components delivered with the mold:
Customer value: Immediate availability of replacement parts eliminates downtime waiting for spares.
Scheduled Maintenance: Every 200,000 shots, Ansix Tech provides mold maintenance services:
Customer value: Preventive maintenance extends mold life and prevents unexpected failures.
Lifetime repair: Repairs available at cost—no captive markup.
Part V: Differentiated Commitments — Addressing Common Industry Pain Points
Common Customer Complaint Ansix Tech's Response Customer Value
"Molds require frequent repairs, disrupting orders" 2,000-shot aging test before delivery with wear report; 3-year structural warranty (excluding normal wear parts) Predictable tooling performance—no unexpected downtime
"Excessive flash, high post-processing costs" 0.005mm fit tolerance on parting lines; self-locking clamp force compensation; flash controlled to ≤ 0.03mm per batch Eliminates manual deburring—saves 3-5% per part
"Dimensional inconsistency batch to batch" Ultrasonic wall thickness sensors with real-time pressure compensation; optional in-mold pressure/temperature sensors for closed-loop control Every batch meets specification—no customer re-qualification required
"Mold repair takes too long" In-house electrode and EDM shop—repairs completed on-site; 24-hour restoration for standard repairs Minimizes production interruption
"Material selection uncertainty" Strategic material consultation with Covestro, SABIC, and other suppliers—custom compound formulation available No over-specification; optimal cost-performance balance
Part VI: TN Series Fuel Level Sensor — Product Overview
6.1 Product Description
The TN series fuel level sensor is a resistive-type level sensor designed for automotive, truck, bus, marine, and genset applications. Key specifications include:
Parameter Specification
Output Signal Resistive: 0~190Ω / 240~33Ω (customizable)
Material SUS304 or SUS316 stainless steel body
Operating Temperature -40°C to +85°C
Ingress Protection IP67
Resolution 21mm (standard, customizable)
Mounting SAE flange mount
Principle Float mechanism with magnetic spring switch; liquid buoyancy and magnetic induction
Special Features Anti-rollover fuel leak prevention; integrated suction and return pipes
6.2 Applications
Light trucks and heavy-duty trucks
Buses and commercial vehicles
Marine vessels and yachts
Engineering and construction machinery
Generator sets (gensets) and stationary power systems
6.3 Manufacturing Process Overview
Step 1: Material Selection — Stainless steel (SUS304/SUS316) selected for the sensor body tube, providing corrosion resistance and durability in fuel environments. Plastic components (floats, housings, connectors) are engineered from thermoplastics selected for fuel compatibility and dimensional stability.
Step 2: Mold Design & Manufacturing — Precision molds manufactured with 0.002mm accuracy for sensor housing components. Insert molding capability for integrated electrical terminals.
Step 3: Injection Molding — Sensor housings, floats, and connector bodies produced on Ansix Tech's 260-machine fleet. Process parameters locked in MES for batch-to-batch consistency.
Step 4: Insert Molding — Metal terminals and inserts placed in mold cavities before injection, creating integrated electrical connections.
Step 5: Assembly — Float mechanism, magnetic switch, and resistive element assembled into the stainless steel tube.
Step 6: Calibration & Testing — Each sensor calibrated on automated test stands to verify 0-190Ω resistance output across the full stroke.
Step 7: Quality Inspection — Full dimensional verification, functional testing, and leak testing before packaging.
Part VII: Material Science Excellence — The Foundation of Sensor Reliability
7.1 Material Selection Philosophy
Ansix Tech's material science approach is strategic, not transactional. The company maintains a comprehensive polymer property database and collaborates with leading material suppliers including Covestro and SABIC.
For TN Sensor Floats: Polypropylene (PP) with a specialized micro-foaming process creates a closed-cell foam structure with precise density control—waterproof, durable, and reliably buoyant.
For High-Temperature Sensor Housings: PPS or glass-fiber reinforced nylon for heat resistance up to 105°C continuous service.
For Fuel-Exposed Components: PBT or PC/ABS blends with demonstrated resistance to diesel, gasoline, and engine oils.
For Corrosive Environments: PVDF (Polyvinylidene Fluoride) for superior chemical resistance.
7.2 Material Cost Optimization
Ansix Tech's integrated approach—simultaneously developing material selection, mold design, and production processes—eliminates the costly friction that typically occurs when material suppliers, mold makers, and processors operate in silos.
Customer value: No over-specification. Materials are selected to meet exact application requirements, not exceeding them unnecessarily.
Cost savings: Eliminates the premium paid for "insurance-grade" materials that don't deliver additional functional benefit.
Part VIII: Quality Assurance — From ISO Certification to Customer Confidence
8.1 Certifications
Certification Scope Customer Value
IATF 16949 Automotive quality management Meets OEM and Tier 1 supplier requirements; facilitates PPAP submission
ISO 9001:2015 Quality management systems Documented quality processes across all operations
ISO 13485 Medical device quality management Demonstrates capability for precision, high-reliability components
ISO 14001 Environmental management Sustainable manufacturing practices
8.2 Quality Control Throughout Production
Incoming Material Inspection: Raw materials verified against specifications with certificates of analysis.
In-Process Controls: MES-locked parameters, real-time monitoring, first-article inspection.
Final Inspection: Full dimensional verification, functional testing, and visual inspection.
Documentation: Full PPAP package available including control plans, FMEAs, capability studies, and dimensional reports.
Part IX: Cost Competitiveness — Systematic Cost Reduction
9.1 Material Cost Optimization
Strategic material selection avoids over-specification
Bulk purchasing power with major resin suppliers
Material waste reduction through optimized runner and gate design
Regrind utilization where material properties permit
9.2 Process Efficiency
28% cycle time reduction achieved through process optimization—same equipment, increased daily output from 1,300 to 1,670 units
Automated part handling and inspection reduces labor costs
MES integration eliminates unplanned downtime
9.3 Tooling Cost Efficiency
DFM analysis prevents expensive mold rework
Standardized mold bases and components reduce manufacturing cost
Long mold life (500,000-1,000,000 shots) spreads tooling cost over more parts
9.4 Vertical Integration
In-house mold manufacturing eliminates outsourcing markup
In-house electrode and EDM shops reduce repair costs
Four production facilities provide geographic cost optimization
Part X: Delivery Excellence — Speed Without Compromise
10.1 Production Capacity
260 injection molding machines across four facilities
30-ton to 2,800-ton clamping force range covers all part sizes
Over 1,200 employees supporting production
200,000+ square meters of manufacturing space
10.2 Delivery Commitments
Service Commitment
Mold manufacturing Standard: 10-60 days depending on complexity
Sample delivery T0-T3 samples with improvement reports
Pilot production 100-500 shots, CPK validation
Mass production Based on customer schedule; flexible capacity
Emergency repairs 24-hour turnaround for standard repairs
10.3 Geographic Advantages
China operations (Shenzhen, Dongguan, Hunan): Proximity to automotive supply chain
Vietnam operations: Cost-competitive manufacturing, tariff advantages
Four facilities provide production redundancy and supply chain resilience
Part XI: Post-Sales Service — Lifetime Partnership
11.1 Technical Support
DFM consultation for new product development
Material selection guidance for new applications
Process optimization for existing products
11.2 Mold Maintenance
Spare parts kit delivered with each mold
Scheduled maintenance at 200,000-shot intervals
Lifetime repair service at cost
11.3 Quality Support
Full PPAP documentation available
8D corrective action reports for any quality issues
On-site support available for critical customers
Conclusion: The Ansix Tech Value Proposition
For customers seeking a manufacturing partner for TN series fuel level sensors—or any precision injection molded components—Ansix Tech delivers:
Reliability: IATF16949-certified quality systems, 28 years of automotive manufacturing experience, and proven process controls that deliver consistent, specification-compliant parts batch after batch.
Cost Efficiency: Systematic cost reduction through material optimization, process efficiency, vertical integration, and design-for-manufacturability—with documented savings of up to 16% on component costs.
Speed: 260 injection molding machines across four facilities, in-house mold manufacturing, and rapid repair capabilities ensure on-time delivery and minimal production interruption.
Partnership: From DFM analysis through prototype validation, pilot production, mass production, and post-sales support—Ansix Tech is an integrated engineering partner, not just a supplier.
Peace of Mind: Full material traceability, documented quality systems, and a 3-year mold structural warranty provide customers with confidence that their supply chain is secure.
As Ansix Tech's engineering philosophy states: "A mold is not just a piece of steel—it's a money-printing machine. We design every mold with manufacturing science,排气 paths, temperature balance, and material flow in mind, ensuring that when it reaches your production line, it runs免调试, low-flash, and with maximum lifespan.
Ansix Tech Co Ltd
If you have any plans related to Fuel tank level sensor (TN sensor) for oil return, filter, automotive fuel tank sensor, resistive fuel level sensor (0-190Ω)
, you can contact us at any time. We will turn your ideas into reality, let you realize your dreams, and obtain large orders from the market. Our contact information is info@ansixtech.com. Or contact our CTO, mail: stephen@ansixtech.com
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