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| Material | PA66-GF30 |
| Process | Precision Insert Molding |
| Components | 4 Metal Pins + 2 Brass Inserts |
| Application | Automotive Sensor Assembly |
| Pin Alignment Accuracy | ±0.05 mm |
| Mounting Hole Position Tolerance | ±0.03 mm |
| First Pass Yield | 98.5% |
This project involved the manufacturing of a compact automotive sensor connector housing using precision insert molding technology.
The component integrates a PA66-GF30 plastic housing, four metal pins and two brass inserts. Due to the tight relationship between electrical connection, mounting structure and sealing interface, the project required strict control of insert positioning and molding consistency.
Dawang Precision supported the project from mold design optimization, insert molding process development to final dimensional inspection.
The four metal pins are the key electrical connection features of this component.
During injection molding, the pins may shift due to resin pressure, mold closing force and material flow.
The main challenge was maintaining stable pin positioning after molding to ensure reliable connector assembly.
The final production process achieved pin alignment accuracy within ±0.05 mm.
Two brass inserts are integrated into the housing to provide durable mounting points.
The inserts needed to maintain accurate positioning during molding while preventing movement, rotation or resin contamination inside the threaded area.
The mounting-hole position tolerance was controlled within ±0.03 mm to support consistent assembly.
Because automotive components require repeatable performance, the molding process needed to maintain stable dimensions during continuous production.
Special attention was given to:
Insert positioning
Material flow balance
Cooling consistency
Flash control
Part deformation
PA66-GF30 was selected for the connector housing because it provides a balance of mechanical strength, heat resistance and dimensional stability.
The glass fiber reinforcement helps improve stiffness and reduce deformation compared with standard nylon materials.
However, proper molding control is required because glass fiber orientation may influence shrinkage and warpage.
A precision insert molding process was developed to secure the metal pins and brass inserts during injection molding.
Dedicated positioning features inside the mold were used to maintain insert location before and during resin filling.
The process focused on:
Accurate insert positioning
Stable material filling
Reduced insert movement
Consistent molded dimensions
The mold design was optimized to achieve balanced filling and minimize deformation.
The engineering team evaluated:
Gate location
Material flow direction
Cooling balance
Parting-line condition
Ejection strategy
These improvements helped maintain the relationship between the connector opening, mounting holes and metal inserts.
Before molding, the metal pins and brass inserts were inspected to confirm their condition and dimensional consistency.
Proper insert preparation helps prevent positioning issues during molding.
The four metal pins and two brass inserts were accurately positioned inside the mold using dedicated locating features.
This step was critical for maintaining electrical alignment and mounting accuracy.
During injection molding, PA66-GF30 material flows around the positioned inserts and forms the final connector housing.
Injection parameters were controlled to achieve complete filling while minimizing stress on the inserted components.
After molding, each component was inspected for:
Metal pin alignment
Mounting-hole position
Connector opening dimensions
Visible flash
Short-shot defects
Surface quality
The validated production process achieved a first-pass yield of 98.5%.
Critical dimensions were inspected to verify the functional accuracy of the connector housing.
Key inspection items included:
Pin alignment
Mounting-hole position
Connector opening
Insert location
The measured results achieved:
Pin alignment accuracy within ±0.05 mm
Mounting-hole position tolerance within ±0.03 mm
The molded parts were inspected for appearance and molding defects.
The validated samples showed:
No visible flash
No short-shot defects
Clean insert areas
Stable molded surfaces
Through optimized mold design, precision insert molding and controlled inspection procedures, the connector housing achieved stable production performance.
The final results included:
Precision metal pin alignment within ±0.05 mm
Mounting-hole position tolerance within ±0.03 mm
No visible flash or short-shot defects
First-pass yield of 98.5%
The project demonstrated Dawang Precision’s capability in manufacturing complex insert-molded components requiring accurate positioning and consistent production quality.
Dawang Precision provides integrated manufacturing solutions for custom plastic components with metal inserts.
Our capabilities include:
Injection mold design and manufacturing
Precision insert molding
Engineering plastic processing
Metal insert integration
Dimensional inspection
Prototype validation
Mass production support
We help customers transform complex plastic and metal integrated designs into reliable production components.
The connector housing was manufactured using PA66-GF30, a glass-fiber reinforced nylon material that provides improved strength and dimensional stability.
Metal pins are positioned using dedicated mold fixtures before injection molding. Mold design and process control help maintain consistent pin location during production.
The project achieved:
Pin alignment accuracy within ±0.05 mm
Mounting-hole position tolerance within ±0.03 mm
If your project requires plastic components integrated with metal terminals, threaded inserts or precision mounting features, Dawang Precision can support your project from DFM review to mass production.
Send your 3D model or drawings for engineering evaluation.
