[Case Study]
Sheet Metal Fabrication of Intake Manifold (Aluminum Die-Cast)
– Achieving Shorter Prototype Lead Time and Cost Reduction in Mass Production –

► Recognizing the Challenges
In the 1990s, aluminum die-casting was the dominant manufacturing method for intake manifolds in the automotive industry. However, rising raw material costs and increased manufacturing expenses due to multi-cylinder engine designs led many parts manufacturers to seek alternative production methods.
Key challenges during the prototyping phase included:
・High cost of mold production
・Lengthy prototype lead times
・Limited flexibility in design modifications
・High costs for small-batch production

►Technical Approach
Our proposed sheet metal fabrication method offers a revolutionary approach that significantly reduces manufacturing costs compared to traditional aluminum die-casting.
Key technical points include:
・Material Selection: SPHC (hot-rolled steel plate) and STKM (carbon steel mechanical tubing)
・Optimized Design: Strength analysis and weight reduction using 3D CAD
・Manufacturing Process: Combination of press forming, laser processing, and welding technology
・Quality Assurance: High-precision dimensional verification using 3D measuring instruments

►Detailed Solutions
The sheet metal fabrication of the intake manifold was developed through the following phases:

1. Design Phase
・3D modeling using CAD
・Design of press molds and jigs for laser processing and welded assembly
・Development of DNC machining programs based on 3D models
2. Prototype Phase
・Mold and jig processing using DNC machining
・High-precision machining with a 5-axis laser cutter
・Precision welding by skilled technicians
3. Validation Phase
・Dimensional verification using 3D measuring instruments
・Performance evaluation through actual vehicle installation tests, followed by design optimization
・Durability testing and feedback-driven design improvements

►Implementation Benefits
This development project achieved the following results:

✔ Manufacturing Cost: Reduced by 40% compared to conventional methods
✔ Development Period: Prototype lead time shortened by 50%
✔ Weight Reduction: 20% lighter than conventional
✔ Design Flexibility: Significantly improved

These achievements were made possible by over 50 years of prototype development experience and a team of 160 skilled engineers. We continue to apply this technology to the sheet metal fabrication of various automotive components.

►Future Prospects
In recent years, some intake manifolds have transitioned to resin materials. However, the optimal manufacturing method depends on the required component characteristics and operating environment.
We propose the best manufacturing solutions, including sheet metal fabrication and hybrid approaches, tailored to each customer’s needs.

►Conclusion
Sheet metal fabrication of intake manifolds is a highly effective solution that achieves both cost reduction and weight savings.
For more details, please download our technical documents from the link below and discuss potential applications with your development team.

[Company Profile]
Company Name: Timec Co., Ltd.
Address: 197-1 Nishigori, Soja City, Okayama, 719-1164, Japan
TEL: +81-866-93-1269
FAX: +81-866-93-2540
Corporate Website: https://timec.co.jp/

🔹 Download Technical Documents:
https://ja.nc-net.or.jp/company/22325/dl/catalog/207206

🔹 Technical Consultation & Quotation Requests:
https://ja.nc-net.or.jp/company/22325/inquiry/

🔹 Related URL: https://timec.co.jp/