Automotive

There is a multitude of potential applications for Molded Interconnect Devices in automobiles that can help reduce component counts, weight and space usage, improve reliability and reduce costs. For instance, MIDs are commonly present in interior locations of vehicles for such applications as adaptive cruise control, headlight sensors, windshield wiper sensors and door/window switches. Other applications include pressure and flow sensors for engine management, air conditioning, crash detection and exterior lighting fixtures. Within these intricate assembly areas, electronic and mechanical functionality are combined through the use of an MID component. They are often implemented due to special design requirements and a focus that is geared toward minimizing space usage and replacing complex sub-assemblies with a single component. Below are two custom case studies highlighting the benefits of MID technology:

An example of a successful implementation of an automotive MID component is a one-piece power rail module that was manufactured for use on Ford Explorers. This component was a bulb holder for a third brake light fixture and was used on an automotive high-mounted stop light. By utilizing MID technology, the company was able to replace the traditional 14-piece insert molded "pigtail" assembly with a single component, fulfilling the designs highest priority, component reduction. This helped eliminate labor costs from assembly while at the same time increasing part quality and reducing the potential points of failure. In the end, not only was the brake light's complexity minimized, but the part also met all required automotive lighting, reliability, safety, and performance standards.

Another instance of a MID part used for automotive purposes was the HVAC blower switch found in the Dodge Minivan. Through a move to MID technology, dodge realized drastically lower tooling costs. It also was able to reduce the overall weight of the sub-assembly by 10%. The 3D MID 2-Shot process helped eliminate the previous manufacturing methods which consisted of die stamping, staking, painting, and lasering steps. This part marked the first case where a high current (17A) was able to be continuously applied to a 3D molded circuit in an automotive application. This was achieved by plating 3 sides of a raised circuit path created during the 2-Shot molding process. Through the elimination of stamped metal busses and connector pins, the base of the blower switch consisted of only a 3D circuit, a housing, and a knob. Like the brake light fixture, the blower switch was able to interface with the automobile's electrical system and provide a clean and reliable solution and greatly simplify the overall assembly.