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Injection Molded Fan Housing

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This project was a nice and simple 2 part injection molded fan cover with honeycomb grill pattern. I was contracted to model

This injection molded fan housing was a nice and simple 2 part injection molded fan housing with honeycomb grill pattern.
I was contracted to model, prototype and produce drawings for injection molding.

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The custom housing is 1.5mm thick with small detailing recesses (just cosmetic). It is part of a existing design that my client is producing for injection molded fan housing covers. This cover is one of a variety of covers that fit to that body.

Constructed with 4x M4 machine screws, the assembly is extremely strong. The assembled case can withstand the weight of 2.5 adult males. Below is the metallic plastic render showing face panel in brushed steel finish. We domed the hexagonal grill pattern to increases stiffness to that weakened are. We found it was aesthetically pleasing as well as functional.

 

Total 3 days work to model, print and submit for tooling so was in very quick project in relation to other more complex designs. Great success and will likely be making more covers in 2020 for Jake. We modelled the mold tool using our standard sized mold base. As you can see its a simple 2 part mold with no undercuts or side cores. The tool did not need cooling channels due to the low volume of mass. The order volume is below 100,000 units so the tool was cut from aluminium.

Above is the solidworks studio renders we produced for marketting visual content. 

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Many electrical products need custom sized housings, we specialise in designing plastic cases of all shape and sizes. Our 3d cad modelling Total 3 days work to model, print and submit for tooling so was a very quick project in relation to other more complex designs. Great success and will likely be making more covers in 2020.

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