Precision Injection Molding: High-Pressure Resistant Housing for
Levelcon's WP01V Sensor
FCE collaborated with Levelcon to design and manufacture the
housing and base for their WP01V sensor, a product renowned for its
ability to measure a vast range of pressure levels. This complex
project demanded advanced material selection, custom injection
molding solutions, and meticulous demolding techniques to ensure
exceptional performance and quality.
High-Strength, UV-Resistant Materials for Extreme Durability
To meet the WP01V sensor's stringent strength requirements, FCE
proposed using high-strength polycarbonate (PC) material. This
material not only offered excellent durability under extreme
pressure conditions but also provided UV resistance for reliable
outdoor use. FCE recommended a 3 mm wall thickness for the housing,
validated through Finite Element Analysis (FEA), which confirmed
the structure's ability to withstand intense pressure without
compromising integrity.
Custom Demolding Solution for Internal Threads
The inclusion of internal threads in the housing posed significant
challenges for the injection molding process, as standard molds
could lead to part sticking during demolding. FCE engineered a
specialized internal thread demolding mechanism tailored to this
requirement. After a detailed explanation of its functionality, the
client approved the solution, ensuring efficient production and
precise thread formation without defects.
Structural and Cooling Enhancements to Mitigate Shrinkage
The housing's thick-walled design increased the risk of surface
shrinkage, potentially impacting both aesthetics and performance.
To address this, FCE optimized the internal structure by replacing
overly thick sections with strategically placed ribs. This
adjustment reduced material concentration while maintaining
structural integrity.
To further enhance cooling efficiency, FCE selected copper for the
mold core due to its superior thermal conductivity. A custom water
channel system was integrated into the mold design, ensuring
uniform cooling across the housing. This approach minimized surface
defects and enhanced both appearance and dimensional accuracy.
Rigorous Testing and Seamless Production Approval
Upon mold completion, FCE delivered sample parts for assembly and
rigorous performance testing. The housings endured extreme
operational conditions without any structural or functional
anomalies. Impressed by the results, Levelcon approved the samples
for mass production. FCE proceeded to fulfill the order on time,
adhering to the highest quality standards.
Key Highlights
This project exemplifies FCE’s expertise in precision engineering
and injection molding, with a focus on:
Pressure-resistant material selection: High-strength PC tailored to extreme applications.
Advanced demolding solutions: Customized mechanisms for efficient internal thread molding.
Innovative design optimization: Structural refinements and enhanced cooling systems for superior
quality.
By combining innovation, technical acumen, and attention to detail,
FCE delivered a robust and reliable solution for the WP01V sensor,
further cementing its reputation as a trusted leader in injection
molding technology.
