Development of a Lightweight Front-End Structure Using Injection Molding Technology

This paper focuses on the development of a lightweight, functionally integrated Front-End Structure (FES) using plastic-metal hybrid injection molding technology. The objective is to achieve modularization, part consolidation, weight and cost reduction. The proposed design integrates multiple components into a single module which makes assembly faster and easier. A mounting strategy with fixation features was added into the structure, which effectively supports various components and sub-assemblies. Component-level Finite Element Analysis (FEA) was carried out which includes static strength analysis, bending and torsional stiffness analysis, modal analysis as well as latch pull test to achieve required structural strength. Ribbing structures were designed and optimized based on FEA result to provide the necessary strength and stiffness to the structure within the minimum weight. Moldflow analysis was carried out to evaluate manufacturability with focusing on gate design, minimizing warpage, and flow balance. Based on Moldflow analysis, necessary design corrections were carried out before tool development for defect-free molding. After validating all performance criteria, the part was manufactured using injection molding process. Compared to conventional sheet metal structures, the thermoplastic FEM achieved an approximate 50% weight reduction while maintaining structural integrity.