Car bumpers are a moulded shell with wiring and other devices embedded. The normal manufacturing process involves clipping a separate wiring harness to the inside of the shell to connect the lighting and sensors.
This project was a concept study carried out to assessed the feasibility of producing car bumpers complete with wiring automatically.
Near Field Communication of all kinds needs an antenna. In this instance the customer was seeking a way of simplifying the supply chain. The existing part requires a 5-step manufacturing process, with an injection moulding, and a stamped metal part glued together. The conductor is then being cut and spring contacts spot welded onto the tracks. Q5D was able to demonstrate how a single bare wire could be laid onto the injection moulded part despite the complex surface. With [...]