General industry: Packaging
LLDPE
Plastic Injection Moulding
Inner Dia :31.2± 0.03
General Tolerances
Critical Tolerances
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A US-based packaging company approached OMPL with an idea to build a leak-proof moulded plastic valve with a rubber flap for its dunnage airbags. They needed a manufacturer with strong design capability who could give shape to their idea as well as custom-build parts at a reduced cost. OMPL fit the bill.
Often, we reverse engineer parts based on the approved samples provided by the client. But in this case, the company didn’t have one. Not only the valve had to meet the client's requirements, but also the strict cargo policies and standards for packaging. We worked closely with the client to ideate and develop the prototypes in our in-house design facility.
Our team began conceptualising a valve with a plastic body assembled with a rubber flap. The main goal was to avoid leakage. After building our first prototype mould, we found deep weld lines and shrinkage due to high wall thickness in the profile area and found leakage during leak testing. Our next task was to eliminate the issues we found in our first prototype.
Our engineers devised a solution by building a split mould (head and flange) to avoid shrinkage and weld line, and both parts were joined through an ultra-sonic welding machine. This time, the prototype passed the leak testing.
The final outcome was a product that came to life with very few iterations and low production costs and successfully met the client's requirements and packaging standards.