CASE STUDIES

Domestic Gas Boiler Front Module

Overview
Project
Ideal Domestic Gas Boiler Front Module
Timeline
September 2015 / November 2016
Direct Customer
Ideal Boilers / Groupe Atlantic UK Ltd.
OEM
Ideal Boilers Ltd.
Volume
400,000 units per annum
Key Project Partners
Engel UK - Injection Moulding Machine
Ceracon UK – Liquid Gasket
Moldsystems / ABI - Toolmakers
IMTech – Moldflow
Hellyar Plastics / Hexpol - Materials
Southfork Innovation – Ultrasonics
PBE Marking - Printing
Specifications
Scope
Replacement of pressed steel front panel with plastic
Integration of sealing into plastic parts
Sub-component integration into plastic parts
Enhanced aesthetics and model variant distinction
Weight reduction
Complexity
39 Injection Mould Tools / 122 finished product variants
Technology
39 Injection Mould Tools / 122 finished product variants
Plasma treatment / Liquid Gasket Application / Automated Assembly
Ultrasonic Heat Stake & Weld
Hot Foil Printing
In Process Vision Testing / Leak Testing
Challenges
Aesthetics
Flatness
Sealing Performance
New Technology Integration
Complex Tooling
Challenging Lead Time

Forging Links with Strategic Partners