Successful Foam Pressing Foam Pressing Jig Project for Refrigerator Doors

Project Overview

The client, an FDI home appliance manufacturer in Vietnam, required the design and fabrication of a foam pressing jig for refrigerator door production. The project aimed to deliver high precision, robust performance, and reliability in a continuous production environment, ensuring seamless operation and quality output.

IDEA was tasked with:

• Machining welded components and the machine frame.
• Assembling mechanical components into a complete product.
• Ensuring the equipment met international standards for precision and quality.

Challenges

1. High precision requirements
   • Mechanical parts and the frame needed a tolerance of less than ±0.2mm to ensure the door gasket’s seal integrity during foam pressing jig.The machine frame had to withstand high pressure during operation.
2. Tight delivery timeline
   • The project had to be completed within four weeks, including design, machining, and assembly.
3. Durability and safety assurance
   • The jig needed to operate reliably in a 24/7 production environment.

Solution

IDEA implemented specific solutions to address the challenges encountered:

1. Machining of welded components and machine frame: Advanced CNC machines, both 3-axis and 5-axis, were used to machine complex mechanical components, ensuring high precision and a smooth finish. TIG welding techniques were applied to ensure both durability and aesthetic quality in the machine frame.
2. Mechanical component assembly: The assembly process was carefully designed in detailed steps, supported by a 3D coordinate measurement system (CMM) to verify the dimensions and accuracy of each part. Precision measuring tools, such as parallelism and squareness testers, were employed to guarantee accurate assembly of all components.

Implementation

1. Frame design and production
   • Constructed the frame using high-strength alloy steel and applied heat treatment to enhance durability.
   • Conducted non-destructive testing (NDT) on welds to ensure quality.
2. Machining of mechanical components
   • Precisely machined smaller components such as gaskets, assembly holes, and contact surfaces using CNC machines.
   • Verified each part’s profile and dimensions using advanced measurement tools.
3. Final assembly
   • Assembled all components and conducted comprehensive in-house testing at IDEA’s production facility before delivery.
4. Testing and handover
   • Performed rigorous real-world testing, including foam pressing accuracy and door sealing performance.
   • Delivered the foam pressing jig after ensuring all functional and quality requirements were met.

Results

1. International-quality product
   The foam pressing jig met all precision, durability, and operational reliability requirements for use in the production line.
2. Early project completion
   Delivered three days ahead of schedule.
3. Improved production efficiency
   Reduced foam pressing defects from 3% to 0.5%, significantly boosting production efficiency.
4. High client satisfaction
   The client praised IDEA Group’s professionalism and quality of service, opening the door for future collaborations.

IDEA’s expertise in designing and manufacturing Foam Pressing Jigs ensures exceptional quality and precision, significantly improving production efficiency. Ready to elevate your manufacturing process? Contact us today to discuss how we can help you achieve outstanding results.