FUNCTIONALITY AND AESTHETICS FOR THE E-MOBILITY SECTOR

GI-BOX by Gimax is a wallbox charging device that combines premium aesthetics with high performance and the strictest adherence to safety standards. This achievement is made possible thanks to the Formula1Partner provided by MPT Plastica, supporting the client in product development from co-design to mold, all the way to the molding of the finished solution.

Gimax, Italian leader in the manufacture of electrical appliances, electrical materials, and electronic components, asked us to create an outer casing that was:

• Robust, with impact resistance and weather resistance compliant with IK10 certification.
• Suitable for prolonged use in private and public spaces.
• Flame retardant, meeting self-extinguishing requirements according to UL94 V0 class.
• Waterproof, even when subjected to washing with pressure washers, with total protection against the penetration of dust and liquids IP55.
• Pleasant-looking with precise fittings.

Discover all the details and operational steps of the project by reading the article.

GI-BOX Wallbox is a Mode 3 charging device, meaning it is a single-phase/three-phase alternating current dispensing point up to 32 A, for a maximum power of 22 kW. Unlike most solutions available on the market, GIBOX is based on an expandable and upgradable architecture to maintain the value of the investment over time.

This charging system is controlled by a mini-computer capable of connecting to the WIFI or LAN network, monitoring the load by adapting it to the available power, and interfacing with the home automation system. The internal electronics are protected by two self-extinguishing, waterproof, and resistant PC/ABS half-shells, ensuring precise fittings and pleasant aesthetics.

The device is designed to be placed in garages or courtyards of homes; in hotel, company, supermarket, dealership parking lots; in various public spaces and urban contexts. To ensure that its style matched its durability over time and could blend in pleasantly and harmoniously with the environment in which it is installed, a clean design was studied, with slightly rounded geometric lines, enriched by a thermoformed ABS painted frame available in 4 color variants: metallic gray, bright red, glossy black, and gentian blue.

Even more relevant in its realization was the aspect of safety. Current regulations, EN IEC 61851, define the constructive and safety specifications. For the version with the panel T2 socket, the EN IEC 62196-1 standard (for Italy, France, England, and SG) imposes the presence of a shutter, i.e., a diaphragm with an additional protective function.

Particular attention was paid to the study of filling, in order to avoid the visibility of the joint lines and the injection point, and to achieve a homogeneous distribution of material in the mold.

To conceal the injection point of the front visible half-shell, it was made to coincide with the point present at the center of the R-FID authentication symbol, which was in turn enlarged and provided with drafts and radii to improve the overall result.

During numerous Moldflow analyses, it was also noticed that junction marks could have been created during molding in the opening intended to accommodate the display. GI-BOX is indeed equipped with a 7-inch touch screen LCD that allows users to configure the various available options according to their needs. To overcome this critical issue, the thickness and chamfer of the window were optimized, allowing the accumulated gases in the filling to escape from the bottom, thus improving the area around the display.

In the lower part of the front shell, the closing step was also modified to strengthen the entire area. Inside, all the elements for fixing the boards, cables, and assembly of the two half-shells via self-tapping screws were provided, as well as the necessary seats for the seals for water tightness. For some columns, where the Moldflow analysis had highlighted the risk of sink marks, together with Gimax, we provided for the use of an alternative cable clamp to the one initially planned, foreseeing only one column shifted to the non-visible part.

Regarding the rear shell, in addition to increasing the various radii of the fixing elements to uniform the thicknesses, to improve the critical points highlighted by Moldflow analysis, we added an injection lens, in order to ‘drown’ the nozzle witness into the plane avoiding protrusions. In addition, ribs were added to the lower part to give it greater strength, reducing the thicknesses where possible, to contain the overall mass of the piece.

As always when it comes to printing class V0 materials, which flow little, like this PC/ABS blend, we resorted to numerous Moldflow analyses to see if it was necessary to modify not only the mathematics of the half-shells but also those of the molds to optimize filling.

For GI-BOX, our technical office designed and built two molds, one for each half-shell. Suitable drafts were applied to the piece mathematics in the direction of movement to avoid the formation of marks on the piece due to friction between the mold movement and the printed part. Necessary adjustments were then made to optimize the filling of the hardest-to-reach areas, facilitate the extraction of the half-shells, avoid sink marks and deformations of the pieces, and achieve the best aesthetic result of the visible surfaces.

In addition, Gimax asked us to provide a version of the front half-shell with a hole sized to insert a socket, in order to offer the market the Wallbox both with a cable output and with a cable output and T2 socket on the front side. To avoid making two different molds with interchangeable inserts, double codes, etc., we proposed to the client to carry out only the centerings, such as those provided for the rear shell.

Once the good filling of the mold and the absence of distortions or aesthetic imperfections of the post-molding object were verified, we moved on to the final phase of design of the equipment. The project was developed in 3D for each individual component with the software available in our internal technical office. Then our mold construction workshop continued with the realization using machinery, milling machines, numerical control electroerosions, and CAM systems.

The ability to solve customer problems is our strength. For this reason, even though our core business is injection molding, the presence within us of a technical office and a mold construction workshop has allowed us once again to support the customer in solving all the problems related to the realization of plastic products and its equipment.

The appeal of GI-BOX Wallbox was so appreciated by the first interlocutors involved in market research that, based on the same design, Gimax has already thought of developing an electrical panel.

If this casestudy was interesting and useful for you and your company, contact us and let’s get to know each other better.