The result in four numbers
The full picture
A Tier 1 customer supplying components to a European rail operator needed a new clamp design for securing wiring harnesses in the passenger compartment. Requirements: compliance with DIN EN 45545-2 R22 and R23 / HL2, weight reduction compared with the existing metal solution, one-handed assembly, a 30-year service life.
Deadline: 14 weeks from the first brief to PPAP documentation. Target volume: 250k pcs per year, delivered in batches every two weeks.
We proposed a design in an FR grade of PA6.6 GF50 from one of our reference material suppliers, with a documented test report for a 1.6 mm thickness - appropriate for the clamp design. The design was optimised in CAD for clip-in assembly and validated in Moldex3D for fibre orientation at critical nodes (mounting snap hooks).
SLA and SLS prototypes delivered to the client in week 3. Injection mould built by a reference EU supplier. PPAP level 3 validation.
Component approved by the end customer (the rail operator) in week 13. First series delivery in week 18.
After six months of production: CPK 1.82 for the critical geometric tolerance, 0 quality complaints, OTD 100%. The client has extended the collaboration with two more projects from the same component family.
Key technical decisions
The three decisions that contributed most to the project's success:
- A material with a documented thickness. Choosing an FR grade whose test report covered a 1.6 mm thickness saved a cycle of additional laboratory testing.
- Simulation before machining. Moldex3D flagged a weld line risk in the mounting snap hook - moving the gate by 5 mm eliminated the problem.
- A prototype in week 3. Delivering a physical prototype to the client early for trial assembly closed the ergonomics discussion before the toolroom started work.
“MS-PROGRESS was the second supplier we spoke to that week. After the first technical meeting, we closed the selection process.” - Project manager on the Tier 1 client side
