Great Wall Motors instrument panel and center console assembly mold

Great Wall Motors instrument panel and center console assembly mold

 

FORGING THE FUTURE'S INTERIOR: HOW ANSIX TECH'S MOLDING MASTERY POWERS GREAT WALL MOTORS' COCKPIT REVOLUTION

[SHENZHEN, CHINA] – In the high-stakes arena of automotive manufacturing, the vehicle’s interior is no longer mere cabinetry; it is the primary human-machine interface, a battleground for brand perception, comfort, and technological integration. At the heart of crafting this critical environment lies a discipline demanding microscopic precision and macroscopic vision: high-precision injection molding. Leading this charge is Ansix Tech, a titan of mold engineering, whose recent completion of a complex instrument panel (IP) and center console assembly project for Great Wall Motors (GWM) stands as a testament to Chinese manufacturing’s ascent into the global premium tier. This project encapsulates a relentless pursuit of excellence, from digital prototype to certified mass production, driven by a singular mission: delivering unparalleled reliability and dramatic cost-efficiency without compromise.

 

The Blueprint: Decoding GWM’s Demand for Excellence

Great Wall Motors, a powerhouse in China’s SUV and pickup segments, demanded a cockpit assembly that balanced rugged durability with sophisticated aesthetics. The specifications were stringent, targeting a combination of Class-A surface finish, structural integrity for airbag deployment and passenger safety, seamless integration of vents, screens, and controls, and resistance to the harsh realities of automotive life—UV exposure, temperature cycling from -40°C to 85°C, and long-term wear.

 

Product standards & Certification Journey:

The project followed the rigorous automotive Product Part Approval Process (PPAP). Ansix Tech’s engagement began at the Advanced Product Quality Planning (APQP) phase. Engineers worked in lockstep with GWM’s design team on the prototype design, employing state-of-the-art 3D CAD and CAE software to simulate part geometry, fit, and function before any steel was cut. This virtual validation was crucial for identifying potential interference, sink marks, and warpage issues.

 

Following prototype freeze, the manufacturing verification phase commenced. This involved producing T0 samples from the first-off molds for dimensional and functional checks. A series of engineering tests—including coordinate measuring machine (CMM) scans, gloss and color matching assessments, and preliminary material property tests—were conducted. Iterative adjustments led to T1 and T2 samples, progressively refining the mold until all criteria were met.

 

The final hurdle was mass production certification (PPAP Level 3 submission). This required documented evidence of process capability (Cp/Cpk > 1.33 for critical dimensions), material certifications, full Material Testing Reports (MTRs), a complete Design Failure Mode and Effects Analysis (DFMA), Process Flow, and Control Plans. Ansix Tech’s systematic approach ensured a smooth sign-off, certifying the mold for high-volume production.

 

The Material Science: Selecting the Polymers for Performance and Economy

The choice of plastic material is a foundational cost and performance decision. For the GWM IP and console, Ansix Tech engineered a strategic material plan:

 

Primary Substrate (IP Carrier & Console Base): A high-performance, low-VOC PC/ABS blend, specifically Covestro’s Bayblend T85 MN or an equivalent grade like SABIC’s CYCOLOY C6200. This material offers an ideal synergy:

 

PC Contribution: Excellent impact strength (crucial for passenger safety), heat resistance (to withstand dashboard temperatures), and inherent rigidity.

 

ABS Contribution: Enhanced processability, lower cost versus pure PC, and good surface quality.

 

This selection avoided over-engineering with more expensive polymers like polyamide (PA) while fully meeting mechanical and thermal requirements.

 

Visible Components (Upper IP Skin, Console Trim): For parts requiring a soft-touch feel or specific graining, Thermoplastic Polyolefin (TPO) or Polyvinyl Chloride (PVC) Slush Skin was specified for skin layers over a substrate. For hard, glossy trim pieces, high-flow PMMA (Acrylic) or Plated ABS was chosen for its superb aesthetic finish and UV stability.

 

Structural Reinforcements (Metal Inserts & Ribbing): Critical mounting points and areas subject to high load (like Steering column support) were designed with ultrasonic or heat-staked metal inserts and reinforced with strategic ribbing designed into the mold, allowing the use of the standard PC/ABS without upgrading to a more expensive, glass-filled composite.

 

Ansix Tech’s value-driven material strategy involved deep collaboration with raw material suppliers to identify grades that offered optimal property profiles at the best commercial value, directly reducing the bill of materials (BOM) cost for GWM.

 

The Digital Forge: Mold Flow Analysis (DFM) as the First Crucible

Before manufacturing, the design was subjected to exhaustive Mold Flow Analysis (DFM). This simulation software predicted how the molten plastic would fill the mold cavity.

 

Objectives: To optimize the gate location for minimal weld lines (which weaken structure and mar appearance), predict and eliminate air traps, balance filling pressure, and simulate cooling time and warpage.

 

Outcome for GWM: The analysis led to a hot runner system with valve gate control for the large IP carrier to ensure balanced filling from multiple points, preventing asymmetric warpage. It also informed the cooling channel layout to ensure uniform heat extraction, critical for achieving a cycle time target and minimizing post-mold distortion.

 

The Anatomy of Precision: Key Aspects of Mold Design & Manufacturing

The mold itself is a masterpiece of mechanical engineering. Ansix Tech’s design philosophy for the GWM project centered on durability, efficiency, and maintainability.

 

Steel Selection: Core and cavity for the primary parts were machined from premium pre-hardened mold steel (P20, 1.2738H) for its excellent polishability and good wear resistance. For high-wear areas like gates and sliding mechanisms, hardened steel (H13, 1.2344) was used. This selective application of premium materials controls cost while ensuring longevity over a planned production life of 1 million cycles.

 

Cooling System / Water Channels: A conformal cooling design was employed where possible. Using 3D metal printing (DMLS) for complex core inserts, Ansix Tech created cooling channels that precisely followed the contour of the part. This dramatically improved cooling efficiency by up to 40%, reducing cycle time—a direct contributor to lower part cost—and ensuring more uniform part crystallization.

 

Runner & Gate System: A hot runner manifold system with 8 individually temperature-controlled drops and valve gates was designed for the IP carrier. This eliminated material waste from cold runners (saving 2-3% of raw material per shot) and provided precise, sequential control over the filling process to optimize packing and minimize internal stresses.

 

Ejection System: Given the part’s complex geometry with deep draws and undercuts, a multi-action ejection system was designed. This included angled lifters, hydraulic core pulls, and a dense pattern of ejector pins with interchangeable sleeves to ensure reliable, mark-free part release without distortion.

 

Manufacturing Challenges & Workflow:

The scale and complexity of the IP mold (over 80 tons) presented significant hurdles. The processing workflow was a symphony of advanced technology:

 

Rough Machining: Large CNC milling centers removed bulk material.

 

Heat Treatment: Applied selectively to cores and inserts requiring extra hardness.

 

Precision Machining: High-speed 5-axis CNC machining achieved the final cavity geometry and surface details.

 

Electrical Discharge Machining (EDM): Used for deep ribs, sharp corners, and texturing that CNC tools cannot reach.

 

Surface Finishing: Teams of skilled polishers manually achieved the Class-A SPI A1/A2 finish on visible surfaces, while texturing was applied via chemical etching or laser engraving to create the desired grain.

 

Assembly & Try-Out: All components were assembled in a controlled cleanroom environment. The first trial shots were meticulously analyzed, leading to fine-tuning.

 

The Art of the Shot: Injection Molding Challenges & Process Optimization

Transferring the mold to the production press introduced a new set of challenges.

 

Injection Molding Challenges:

 

Warpage Control: The large, flat sections of the IP were prone to warping due to uneven cooling or residual stress. Ansix Tech’s process engineers used a Decoupled Molding (Scientific Molding) approach, separating the filling, packing, and cooling phases to optimize each.

 

Sink Marks: These were mitigated by optimizing packing pressure profiles and ensuring adequate cooling at thicker sections like rib intersections.

 

Surface Defects: Jetting, flow lines, and gloss variations were eliminated through precise control of injection speed profiles and mold temperature (using vario-temperature technology: hot for fill, cool for set).

 

Process Optimization for Efficiency & Cost Control:

 

Cycle Time Reduction: Conformal cooling, optimized ejector sequences, and robotic part removal integrated with the press’s dry-cycle time shaved 15 seconds off the initial cycle, translating to thousands of additional parts per month.

 

Energy Savings: The efficient hot runner system and optimized clamp tonnage requirements reduced overall energy consumption per part by an estimated 8%.

 

Scrap Reduction: Through rigorous process window establishment and real-time monitoring (using IoT sensors), the first-pass yield rate was pushed above 99.5%, virtually eliminating material and energy waste.

 

The Unblinking Eye: Quality Control and Assurance

Ansix Tech’s quality regime is embedded throughout the process. For the GWM project, this included:

 

In-Process Inspection: On-machine probing during mold manufacturing, and real-time monitoring of injection parameters (pressure, temperature, time) during production.

 

First/Last Article Inspection: Full CMM checks and functional gaging for every production run’s start and finish.

 

Statistical Process Control (SPC): Tracking of critical dimensions (e.g., mounting hole locations, clip post diameters) to predict and prevent deviations.

 

Durability Testing: Regular sampling for mechanical tests (tensile, impact) and environmental tests (heat aging, humidity resistance) to ensure continued compliance.

 

The Final Mile: Packaging and Rapid Delivery

Understanding that the mold is a critical-path item, Ansix Tech orchestrated a Rapid Delivery Protocol. The mold was designed in modular sections to allow parallel machining. Critical path components were prioritized. For shipping, the multi-ton mold was disassembled into major sub-assemblies, each custom-crated in shock-absorbent, humidity-controlled packaging with RFID tracking. A dedicated project manager ensured all documentation—mold manuals, spare parts lists, maintenance schedules—was digital and physical, ready to accompany the shipment. The entire process, from design approval to delivery of production-certified molds, was compressed by 30% versus industry standard for a project of this complexity, accelerating GWM’s time-to-market.

 

Ansix Tech: Delivering Reliability and Value by Engineering Out Cost

The Great Wall Motors instrument panel and console project is not merely a case study in technical capability; it is a blueprint for value-engineered manufacturing. Ansix Tech’s decades of industry experience are distilled into a proactive approach to cost management:

 

Material Intelligence: Recommending material grades that meet, but do not exceed, specifications, leveraging supplier partnerships for best value.

 

Process-Driven Design: Using DFM and mold flow to design manufacturability into the part from day one, preventing costly mold rework.

 

Efficiency by Design: Investing in advanced mold features (conformal cooling, hot runners) that have a higher initial cost but a rapid ROI through dramatically reduced cycle times, energy use, and material scrap.

 

Lifecycle Stewardship: Building molds for durability and easy maintenance, reducing total cost of ownership over their entire production life.

 

Through this holistic philosophy, Ansix Tech achieved a documented overall component cost reduction of approximately 5-7% for GWM on this project—a monumental saving when projected over a production run of hundreds of thousands of vehicles. This saving comes not from cutting corners, but from adding intelligence, precision, and foresight at every step.

 

In an industry where the interior defines the experience and margins define success, partners like Ansix Tech are indispensable. They are the unseen architects of the modern automotive cockpit, forging the tools that shape not just plastic, but the very perception of quality and value on the road. For Great Wall Motors and the industry at large, the message is clear: in the pursuit of automotive excellence, mastering the mold is not just a step in the process—it is the foundation of competitiveness.

 

 

Ansix Tech Co Ltd

If you have any plans related to Great Wall Motors instrument panel and center console assembly mold , 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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