Jin Dasen X Booling
The Jin Dasen team and our Booling engineers, they used Booling’s blow molding tech and quickly took care of all those complicated routing and condensation control problems with the rear air duct.
The Collaboration Between Jin Dasen and Booling
The Jin Dasen team is in the assembly shop, waiting for the trial assembly results of the rear air duct. This duct must pass through the complex internal structure of the instrument panel to reach the vents of the third-row seats. This means the duct not only needs to achieve a 3D curved path within a limited space but also must meet stringent requirements for airflow distribution, condensation control, and NVH performance. More importantly, the OEM requires full lifecycle traceability for every duct—from raw materials to final assembly.
Challenges And Difficulties
Complex Geometry And Space Constraints
The rear air duct must pass through the crowded instrument panel, bypass multiple wire harnesses and structural reinforcements, and achieve multiple 3D bends. It is very difficult to meet these complex geometrical requirements using traditional extrusion processes.
Condensation And NVH Performance
Temperature differences can easily cause condensation on the duct surface. Additionally, the airflow noise (hissing) must be strictly controlled to prevent noise from entering the passenger cabin. This poses challenges to both material and structural design.
Full Traceability
The OEM requires quality control and problem traceability at every stage, from raw material pellets and blow molding to finished product inspection, while also meeting supply chain transparency audit standards.
Flexible Changeover for Multiple Configurations
For the same vehicle platform, Booling can provide both three-row and two-row seating configurations, but the duct lengths and interface requirements differ. The production line supports rapid mold changeover, enabling efficient small-batch, multi-variant production.
Solutions
Facing the complex spatial layout of the rear air duct and tight production deadlines, the Jin Dasen team urgently needed a partner with both process expertise and flexible responsiveness. Leveraging its technical advantages in blow molding, Booling worked closely with Jin Dasen to provide comprehensive support from design optimization to mass production.
“With tight timelines, high requirements, and the need to address both condensation and noise isolation, we were quite frustrated,” said the project leader from Jin Dasen. “But the Booling team not only worked with us on design optimization, but also solved both pain points in one go with their multi-layer co-extrusion process. What truly reassured me was their traceability system—every data point for each part is traceable. This means we deliver not just products to the OEM, but transparent trust.”
Custom Stamping Die Service
Our full-service solution covers mold design, machining, and trial runs for rapid prototyping and flexible small-to-medium volume production, tailored to your needs.
Breakthroughs
Collaborative Structural And Process Innovation
Booling used CFD flow field analysis to optimize the duct’s cross-section and bend radius, reducing pressure loss by 15% while maintaining airflow. By adopting multi-layer co-extrusion blow molding, they integrated an inner layer for condensation prevention and an outer layer for noise isolation, solving two major technical challenges in a single forming step.
Flexible Production Line for Rapid Response
Equipped with a quick mold change system, changeover time can be reduced to under 20 minutes, ensuring on-time fulfillment of multi-configuration requirements.
Zero-Defect Quality Control
Through leak testing and visual dimensional inspection, we can reject defective parts (100% rejection rate). Regular process capability analysis ensures that Cpk values for critical mounting point dimensions reach ≥ 1.33.
Customer Testimonial
“Booling not only supplies high-quality rear air ducts, but also helped us achieve supply chain transparency through their digital traceability system. Booling’s engineering team worked closely with us—their deep understanding of thermal management systems and technical accumulation in multi-layer co-extrusion processes ultimately delivered these outstanding results. They are a trusted and excellent partner for us.” — Purchasing Director, Jin Dasen
