Automotive Air Duct Manufacturing Case: JHS-490D High-Output Solution
| Customer Nation: Canada | Industry: Automotive Parts | Resin: HDPE |
| Machine Model: JHS-490D | Cavities: 2+2 (one station) | Number of station: 1 |
| Actuator Type: Hybrid (with Servo system) | Productivity: 514 pcs/hr | Product type: Air Duct |
Customer Background
As one of the largest automotive parts manufacturing companies in North America, this customer operates globally, supplying critical engine and cabin components to leading OEMs. They sought a more efficient way to produce complex automotive air ducts, which are traditionally difficult to mold due to their irregular shapes and high requirement for dimensional accuracy. They reached out to Jonh Huah to explore if Extrusion Blow Molding (EBM) could replace more complex and costly molding fields while maintaining Tier-1 automotive standards.
Technical Challenges
Automotive air ducts often have delicate, flat shapes with "dimple points" that require absolute wall thickness consistency to avoid structural weakness. In addition, the customer wanted to move from a standard 1+1 cavity setup to a 2+2 mold to significantly increase throughput without increasing factory footprint. The major technical hurdle was implementing reliable "auto-cutting" within the mold mechanism for such complex shapes. Failure to achieve precise in-mold cutting would lead to high scrap rates and increased manual labor, defeating the purpose of upgrading the blow molding machine.
Our Solution
Jonh Huah’s R&D department engineered a high-output solution based on the JHS-490D Hybrid Blow Molding Machine. We designed an innovative mold mechanism featuring integrated auto-cutting technology that operates flawlessly within the cycle. This enabled the transition to a 2+2 mold setup, effectively doubling the output to over 500 pieces per hour in a single station. We also optimized the machine’s multi-point parison controller to ensure uniform thickness across the flat areas and dimple points, meeting the customer's strict tolerance requirements.
Results & Testimonials
The in-mold auto-cutting mechanism allowed the customer to increase air duct output without adding a separate trimming process. After production trials, the customer placed an order for additional Jonh Huah machines for their Mexico factory. Their engineering team highlighted the stable auto-cutting operation and the reduced need for secondary labor as the main reasons for the follow-up order.
Why Choose Jonh Huah?
Jonh Huah excels as a blow molding manufacturer that pushes the boundaries of standard EBM technology. We specialize in servo-hybrid systems and customized in-mold automation that solve the most difficult manufacturing bottlenecks. If you are looking to increase your output for complex industrial or automotive parts, Jonh Huah offers the precision engineering and high-reliability equipment you need. See related industrial case studies or contact us to discuss your production for more efficient production.