Automotive Industry
A faulty LiDAR bracket caused an EV maker’s recall of 12,000 vehicles. Vibration-induced fatigue cracked the mount – misaligning sensors and triggering false collision warnings.
Automotive Tier 1/2 suppliers struggle with sheet metal parts that survive harsh road conditions. Vanmodel sheet metal solutions for BMW, Tesla, and BYD suppliers fix these failures:
The Vibration Killer: 3 Engineering Secrets
- Topology-Optimized Designs
- We use Altair simulation to identify stress concentrations in brackets/mounts
- Result: Redesigned a brake sensor bracket to withstand 20G vibration (up from 8G)
- Fatigue-Resistant Materials
- 6061-T6 Aluminum: 35% higher fatigue strength vs. standard 6061
- Precision Stamping: ±0.05mm tolerance on AMADA servo presses prevents micro-cracks
- Damping Integration
- Laser-cut elastomer slots absorb resonance
- Electrically isolated mounts prevent EMI in ADAS enclosures
Speed Advantage for EV Startups
- 15-Day Tool-and-Die: Progressive stamping dies for high-volume runs
- Prototype-to-Production: Same AMADA RG-100 press used for 5-piece samples and 50,000-unit batches
- Surface Treatment: E-coating, zinc-nickel plating for corrosion resistance
Automotive-Grade Capabilities:
- Tolerance: ±0.1mm on stamped parts
- Materials: HRC 45 high-strength steel, Al 6061-T6, copper-nickel EMI shielding
- Compliance: IATF 16949-ready processes
Vanmodel sheet metal sensor mounts passed 1,000-hour salt spray and vibration tests on first try – saving $250K in validation rework.
Stop Vibration Failures Now
Request a Free Vibration Simulation Report for Your Design
