Custom Mold Design Service
Our mold design provides complete mold design solutions for processes such as injection molding and blow molding. It reduces the number of mold trials, ensuring product consistency and stability in production.
Booling's partnership with Audi
Audi needs to carry out left-right mirror development of key structural components such as the main and secondary instrument panel air ducts. Right-hand drive models not only involve a comprehensive adjustment of the cockpit layout, but also pose new challenges regarding the spatial adaptability of components, lightweighting levels, and the delivery capability of the global supply chain.
Challenges And Difficulties
High-Precision Assembly Requirements
The original left-hand drive air duct needed to undergo mirror development. On the right-hand drive vehicle, the positions of the steering column, pedal box, and wiring harness all changed, requiring a reallocation of space. This means some parts cannot be simply mirrored and need to be redesigned.
Stringent Standards in RHD Markets
This product needs to be targeted at right-hand drive markets such as Commonwealth countries and Japan. These regions have very strict regulations. The components must comply with ECE standards, meet higher environmental requirements, and also fulfill local supplier access thresholds.
Balancing Lightweighting and Stiffness
The right-hand drive model has an additional load from the right-side steering mechanism compared to the left-hand drive model. Therefore, the stiffness of the crossmember must be maintained, while the lightweighting level cannot be poorer than that of the left-hand drive model. Both requirements must be achieved simultaneously.
Traceability for Global Delivery
Audi requires all exported components to have full lifecycle traceability. When any part has a quality issue, the root cause must be traced within 15 minutes to address after-sales service and regulatory audits in overseas markets.
Solutions
Collaborative Design And Mold Flow Optimization
Our engineers worked synchronously with Audi to adjust the right-hand drive data. Using CAE analysis, they optimized the crossmember wall thickness and the duct routing. As a result, the weight was reduced by 8% while maintaining product stiffness. Additionally, the right-hand drive version added a new steering column mounting point, for which we adopted a local insert injection molding process to ensure long-term product reliability.
Development of Dedicated RHD Molds
Building directly on the left-hand drive mold foundation, we quickly developed a dedicated mold base for the right-hand drive version, shortening the development cycle by 30%. For the air duct section, a slider core-pulling mechanism was used, which solved demolding difficulties caused by the irregularly shaped space in the right-hand drive vehicle.
Full-Process Digital Traceability
All processes were recorded—from raw material batch numbers and injection molding parameters to CMM inspection data and packaging logistics. This data was then connected to Audi’s global quality system, truly achieving transparent visibility from order to finished part.
Breakthroughs
Thanks to Booling’s integrated molding and digital traceability capabilities, this project not only achieved rapid mass production of the right-hand drive model but also delivered a 98.5% pass rate on first-round OTS samples and mass production parts just 35 days after mold T0, enabling Audi’s right-hand drive models to launch in overseas markets on schedule.
Customer Testimonial
“Booling has produced left- and right-hand drive air ducts for us that have exceeded our expectations in both precision and performance. Despite the tight timeline of the right-hand drive project, Booling not only achieved a 98.5% pass rate on the first-round OTS samples but also helped us reduce weight by 8% — a clear demonstration of their technical strength. What gives us even greater confidence is Booling’s service — from design handover to mold development, they have always responded quickly and communicated smoothly. Without a doubt, Booling is a long-term, trustworthy partner for us, and we are very willing to continue working with them on future new models.”——Audi’s Purchasing Director
Mold Design Services We Offer
Custom Injection Mold Services
We provide mold design services for injection molds, including gate design, edge gate, hot runner, and more.
Custom Stamping Die Services
We provide mold design services for stamping dies, extending die life and improving material utilization in die manufacturing.
Our Mold Design Process
Product Analysis and DFM Report
At this stage, we can provide customers with feasibility assessments including wall thickness evaluation, draft angle, and undercut analysis.
Mold Structure Concept Design
At this stage, we can determine the parting line, number of cavities, and gate type for the product.
Simulation Verification
At this stage, we can perform cooling analysis, flow analysis, and structural strength verification for the product.
Design Drawings
At this stage, we can provide 2D assembly drawings and 3D mold drawings for the product.
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