Front Cowl Mould

Though electric car has no engine or radiator to protect, many automakers still order a front cowl mould to make grille. Some use it for strictly design elements, some for cooling the battery system and also, a radiator cowl can be part of the aerodynamic features car makers implement to boost speed, while reducing wind drag.
So it is very important to have a good grille design, basic elements here as follows:

1.Design Conception
Laws and regulations

1.Functions
Matching with peripheral accessories
Assembly process
Molding process
Light weight & low cost

2.Grille product construction design
2.1 laws and regulations: for front cowl the fillets of external projections that can be touched by sphere with diameter of 100mm should be more than 2.5mm in radius; relations between cracks distance and fillet radius on the part and material use should follow the clauses.
2.2 functions: good appearance and feature of brand if need; for cooling the required air pass area should be over 1/3 that of radiator, so when calculating projected area the radiator size and position can not be ignored.
2.3 Injection molding process feasibility
Normally ABS is the main material to use for cowl grilles, and we have to notice several things for radiator grille tooling and its moulding process:
No defects on visible surface such as parting line, weld line, sink mark.
No ejecting failure and de-moulding problems for the grill mould tooling.
Tough and assembly feature required.
2.4 Assembly process
Buckling the grille to the bumper body with clips is an easy way for assembly, while be aware of the buckle joint angle, or to use screws can make it better fastened and make sure the screw assembly housing should be located on the lines as possible to rid sink marks. The radiator grille is also fastened to the engine hood by screw for some automobile models.

3 Testings list
High temperature test
Low temperature test
Temperature alternating test
Optics aging test
Solvent resistance test
Material test

4 Remarks
4.1 Method to measure gaps on the grille

4.2 Grille developing cycle table
It is the time table for product developing that from front cowl grille design to off-tool-sample including the radiator injection mould manufacturing and inspection.
4.3 DFMEA
Design Failure Mode and Effects Analysis (DFMEA) should be done during the period.

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