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Automotive

The Benefits of Structural Foam Molding

To give you a greater view of the process, a company may use this innovative process called structural foam molding to produce the most efficient and high-quality product.

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The Benefits of Structural Foam Molding

Structural foam has several uses and not just for companies but the average family as well. Though, why should you use it, and what is structural foam exactly? Structural foam is a low-density material with a spongy texture. It is the result of combining a polymer with nitrogen or injecting it with a chemical agent during the molding process.

To give you a greater view of the process, a company may use this innovative process called structural foam molding to produce the most efficient and high-quality product. The plastic is heated until it becomes liquid, but it can still be injected quickly into the standard injection tool.

Once inside of this cavity, though, there’s one significant change: blowing agents are added that react when they come in contact with air molecules. This causes them to create bubbles and reduce shrinking post-production processes like painting or millwork because of its honeycomb or sponge structure on interior and exterior surfaces.

Here are some more benefits of using structural foam molding:

1. Quick and flexible

The unique manufacturing capabilities of structural foam molding mean that it is a vital part of the supply chain of many major industries. Molded IML packaging provides a quick turnaround for mass production in automotive, aerospace, and marine applications.

Like other injection molding processes, structural foam molding offers a high degree of design flexibility. The process’s versatility allows designers more freedom when choosing the suitable material for the application. This helps deliver components that are optimally designed, cost-effective, and ideal for mass production.

Design for Manufacturing

2. Design for Manufacturing

Because structural foam molding is an injection process, designers can get CAD data into the hands of manufacturers more quickly than with other methods. This can help ensure that products meet design specifications earlier in the development process, preventing costly redesigns and optimizing production times.

3. Paying for durability

Structural foam molding is a relatively low-cost manufacturing process as it requires more miniature tooling than technologies such as die casting or investment casting. It also often requires minor post-processing due to its unique material properties; low heat requirements mean using secondary processes such as grinding or polishing is not always necessary.

Using materials with superior mechanical and physical properties, companies can deliver products resistant to wear and tear in extreme environments – making structural foam molding an ideal solution for manufacturing high-value components.

4. The places to buy

Though not every part is an ideal candidate for structural foam molding, it can be a great solution when you need to lower the weight of your product and produce it in large quantities. With its fast production time and low cost-of-goods during manufacturing phases, this could work well if what’s most important are factors such as strength or durability.

From prototyping to final production, companies like HSV-TMP can find the perfect way for your product idea. They have decades of experience designing and manufacturing plastic components, so they know what it takes to make an excellent finished product that meets their customers’ expectations.

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Automotive

How MEMS Mirrors can make LiDAR Economical

All of this was made possible via MEMS mirrors. Do you know how they can assist in lowering the cost of LiDAR?

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7 Latest Tech Automobile Advancements

LiDAR is a complex technology that has gone through many adjustments and upgrades before becoming efficient and accessible for an average consumer. The bulky and expensive LiDAR has been dramatically improved as a consequence of continuous improvement. All of this was made possible via MEMS mirrors. Do you know how they can assist in lowering the cost of LiDAR?

While LiDAR systems struggled with its fundamental problems such as high cost, big size, limited edition, and low efficiency, technology has found a solution in the form of a MEMS scanning mirror.

1. What is LiDAR?

LiDAR is a light and range sensor or laser projection with distance detection. They became trendy after introducing the first uncrewed vehicles; for example, in uncrewed Yandex automobiles, the LiDAR sensor aids in orienting the vehicle in space.

The term LiDAR refers to the use of light to track the position of objects on a plane. The technology was developed in the 1960s. It was initially designed to track satellites and military targets. Later on, technology permeated other aspects of human life.

2. Key Challenges of LiDAR

Any technology sooner or later starts experiencing difficulties. LiDAR is no exception. Although, in theory, everything seems to be ideal, the reality shows that LiDAR struggles with the following issues, which limit its ability to be widely used and make it expensive:

Automated headlight control

  • It needs a mechanical mirror to deflect the laser beam;
  • Mandatory use of motor for rotation of mirror about its axis;
  • The engine consumes a significant amount of power;
  • The machine is substantial.
  • The high cost of mirrors;
  • Such an extensive system is frequently heavy and can only be integrated into large applications;
  • Many LiDAR applications necessitate a wide field of view.

3. What Are MEMS Mirrors?

MEMS (Micro-Electro-Mechanical Systems) are mechanical structures that can be miniaturized and fully integrated with electrical circuits. These microscopic electromechanical components can perform computational and communication functions while consuming very little power and tiny size.

4. Does LiDAR Work With Mirrors?

LiDAR sensors based on MEMS mirrors are a promising solution. MEMS mirrors have a well-developed silicon design that has proven to be effective in various automotive applications.

MEMS mirrors have many advantages for LiDAR, including:

No need for rotating components. As a result, the MEMS-based LiDAR system is more robust and more durable than the mechanical LiDAR system;

  • Market accessibility;
  • Compactness;
  • Small deflection angles.

A team of researchers from the University of Florida developed a prototype of the LiDAR system using the property of MEMS mirrors to deflect the laser. Not only does the novelty have a wide field of view, but it also consumes very little power. Moreover, due to its small size, it can be easily mounted in small applications.

In the LiDAR system, this feature of MEMS mirrors is used as a scanning element. As a result, the LiDAR device can be powered by a 9V battery charge. The LiDAR prototype also includes an infrared sensor, which is activated only when specific parameters are met.

The prototype has a simple design, but it is one of the bulkiest and energy-intensive components of LiDAR systems. As a result, it is ideal for residential and commercial applications that use intelligent environmental control systems. The developer team plans to improve the LiDAR system by reducing its size and power consumption.

The smaller volume and lower cost of the LiDAR will aid in its integration into a wide range of applications, such as various sensors and control systems that can display the immediate environment. We anticipate that consumer interest in future LiDAR based on MEMS scanning mirrors will increase.

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