AC Cover
AC cover frame with unique design and high quality
Manufacturing
Number of Parts
90%
Reduction
Final Reduction Cost
20%
Reduction
Structure Weight
50%
Reduction
Material Waste
0%
Number of Manufacturing Stages
80%
Reduction
Challenge:
Zamil Air Conditioners faced significant issues with the complexity and cost of their traditional AC cover frames, which involved multiple parts and manufacturing stages. These frames were heavy, requiring extensive material and frequent maintenance. The need for a more efficient, lightweight, and cost-effective solution was paramount to reduce production costs, simplify assembly, and improve overall product performance.
Solution:
Namthaja proposed the use of 3D printed ASA Glass Fiber AC cover frames. The solution involved:
- Design for Additive Manufacturing (DFAM): The original AC cover frame was re-engineered, reducing the number of parts from 37 to 9 by consolidating components into a single structure.
- Material Selection: ASA Glass Fiber was chosen for its UV resistance, mechanical strength, and suitability for outdoor applications.
- 3D Printing Technology: The frame was produced using Pellet-Based Additive Manufacturing (PBAM) with a robotic arm, allowing for large-scale printing and high design flexibility.
- Increased Efficiency & Reliability: The new frame design significantly reduced the number of manufacturing stages by 80% and the overall weight by 50%, enhancing both efficiency and durability.
- Lead Time Reduction: The optimized 3D printing process streamlined production, reducing lead time and increasing productivity.
- Cost Efficiency: Overall costs were reduced by 20% due to lower material usage, simplified assembly, and reduced waste. Enhanced Performance: The new AC cover frame provided better performance with fewer parts, less maintenance, and higher structural integrity.