A Study on mPPO Development and Injection Molding Process for Lightweight Stack Enclosure of FCEV

The automobile industry is focused on eco-friendly vehicles with the goal of carbon neutrality (Netzero), and vehicle weight reduction is essential to achieve high fuel efficiency for driving performance and distance compared to internal combustion engines. This is important for the light-weight stack enclosure of FCEV. Moreover, mPPO needs to be developed with injection molding for the replacement of existing material (aluminum). For this purpose, this study develops mPPO and presents it through physical property tests, predicts the injection molding process flow system for stack enclosure production, proposes injection molding process conditions to secure productivity, and verifies conditions through mechanical stiffness analysis. As a result of the analysis, the runner system with pin-point gate and tab gate’s sizes are proposed. In addition, injection molding process conditions were proposed with the results of cycle time 107.627 s and reduced weld lines. As a result of the strength analysis, it can withstand the load 5933 kg. Therefore, it is possible to reduce weight and material costs using the mPPO existing manufacturing process with existing aluminum, and it is expected that there would be effects, such as reducing the production cost by securing productivity through reducing cycle time.