Your Advanced Molding Partner for the New Energy Era

The transition to new energy solutions demands components that operate at the limits of performance and safety. Failure is not an option. At Livepoint, we understand that success is defined not just by what we make, but by the potential problems we eliminate throughout the molding process.

We proactively engineer-out risks to ensure the integrity, safety, and longevity of your most critical components.

1. Combating Electrical & Thermal Failure

The Risk: Short circuits, current leakage, dielectric breakdown, and material degradation under high thermal loads.

Our Proactive Mitigation:

• Material Science Expertise: We meticulously select and test high-performance polymers with certified CTI (Comparative Tracking Index), high HDT (Heat Deflection Temperature), and UL94 V-0 flame retardancy to meet stringent automotive (e.g., USCAR) and electrical standards.

• Precision Mold Flow Analysis: We simulate the filling and packing phases to prevent weld lines in critical insulating areas and ensure uniform fiber orientation in conductive compounds, guaranteeing consistent electrical properties.

• Controlled Cleanliness: We implement controlled environments and handling protocols for sensitive components like battery connectors to prevent particulate contamination that could lead to electrical failure.

2. Ensuring Structural Integrity Under Stress

The Risk: Part deformation, creep, cracking, or failure due to mechanical stress, pressure, or long-term environmental exposure.

Our Proactive Mitigation:

• Robust DFM (Design for Manufacturability): Our engineers collaborate with you from the outset to optimize wall thickness, add strategic ribs, and eliminate sharp corners to mitigate stress concentration.

• Advanced Gate & Cooling Design: We optimize gate locations and cooling channel geometry to control shrinkage and warpage, ensuring parts meet critical dimensional tolerances for perfect assembly and function.

• Long-Term Performance Testing: We go beyond initial specs, performing accelerated aging and environmental stress tests to predict and design for long-term performance.

3. Preventing Chemical & Environmental Degradation

The Risk: Swelling, embrittlement, or corrosion caused by exposure to coolants, battery electrolytes, chemicals, or UV radiation.

Our Proactive Mitigation:

• Application-Specific Material Validation: We have extensive experience testing material compatibility with a wide range of chemicals used in new energy applications, ensuring we specify resins with proven chemical resistance (e.g., PPS, PPA for harsh environments).

• Protective Finishes & Coatings: Where necessary, we integrate capabilities for secondary processes like plating or applying protective coatings to enhance UV and chemical resistance for exterior components.

4. Achieving Gas & Liquid Tight Sealing

The Risk: Leaks in battery housings, fluid management systems, or outdoor enclosures, leading to system failure and safety hazards.

Our Proactive Mitigation:

• Integrated Sealing Solution Design: We design parts with integrated sealing grooves and gasket interfaces, ensuring compression limits are met without stress relaxation over time.

• Process Stability for Consistency: We utilize scientific molding principles to maintain ultra-stable process windows. This eliminates variations in part density and dimensions that are the primary cause of sealing failures in high-volume production.

5. Managing High-Volume Production Consistency

The Risk: Inconsistent part quality, color variations, and dimensional drift over millions of cycles, leading to line stoppages and recalls.

Our Proactive Mitigation:

• Full Automation & Robotics: Our automated production cells with in-line vision inspection and automated sprue pickers ensure consistent cycle times and eliminate human error, part-after-part.

• Real-Time SPC (Statistical Process Control): We monitor critical process parameters in real-time, allowing for immediate intervention long before a part falls out of specification.

• Comprehensive Tooling Maintenance: Our proactive mold maintenance and cleaning schedules prevent unforeseen downtime and ensure tooling longevity, protecting your supply chain.