The automotive industry is full of different applications requiring die-cut components. From large to small, automotive components often require consistent, accurate, and automatic placement.
Keep reading to learn more about an automotive electronics manufacturer that needed a high volume of small parts and a converter with a solution to efficiently and precisely place them.
The Application Challenge
A Marian customer required a washer to serve as a gasket for their engine controller (EC). The small gasket would be placed where two metal cast halves were attached on the EC. Since there were other electronic components within the assembly, the gasket also needed to shield the EC from electromagnetic interference (EMI).
As with most automotive applications, a high volume of these EMI gaskets (4,000,000 annually) would be required and need to be placed rapidly and accurately. This was essential for the customer to meet their production efficiency and quality metrics.
Enter the Marian engineers!
An example of an engine controller (EC). For this customer's application, a small gasket was needed where two metal cast halves were attached.
Marian's Custom, Die-Cut EMI Solution
Our team designed an extremely small EMI gasket (.256" x .157"), die-cut using Parker Chomerics S6305. This material is an electrically conductive silicone rubber laminated with PSA on one side, measuring only 0.032" thick.
We also suggested accurate and automatic placement using the AccuPlace system. Despite the small size, the gaskets and placement method worked flawlessly, including a specialized process we designed to easily remove the center slugs uniformly. Our team's design ensured both height and width accuracy on the standoff surface.
Small, electrically conductive washers on a roll, next to a pen for scale.
Benefits of Working with Marian for Custom EMI Parts
- Marian excels in "Design for Manufacturing" for our customers. We made every gasket count in this application by developing a process to remove the center slugs from the washers. New capabilities are always being developed by our team to improve processes for our customers' unique situations.
- Marian can recommend systems for rapid and automatic placement of parts at high volume. Parts can be provided on rolls to assist with assembly.
- Our engineers can suggest materials that not only meet the requirements of the application but also are a cost-effective solution that isn't over-engineered for what your application needs.
- We have the capability to accurately cut parts to extremely small sizes and tight tolerances. Let us know how we can assist with your application!
- Laminating multiple materials together for one finished component is our specialty! If your application needs or would be improved by the addition of another (or multiple) thin, flexible materials like filters, meshes, foams, adhesives, films, and more, our teams can engineer a multi-layered solution specific to your custom application.
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Marian, Inc. is an ISO 9001 certified converter of custom die-cut components made from flexible materials. We partner with leading material suppliers, and our global capacity is unmatched. This Marian application story, along with many others, uniquely demonstrates our state-of-the-art custom converting capabilities including die cutting, lamination, design for manufacturing, and more. Please contact us today to learn more or to request a quote, prototype, or material sample.
