Client Cases · FIPFG In-situ Foaming Sealing · Two-Component PU Foam Dispensing · Sealing for Automotive Electrical Control Cabinets and Door Panels

Tesla Door Module Panel FIPFG Foam Sealing: WINMAN INDUSTRIAL WM601 Fully Automatic Dispensing Solution

For Tesla on-board electrical control cabinet and door panel sealing applications, WINMAN INDUSTRIAL introduced the WM601 two-component PU fully automatic FIPFG dispensing solution. To address issues such as material caking, pipeline blockage, and insufficient stability in semi-automatic processes, the solution reengineers high-precision path dispensing, dynamic mixing, online metering and ratio control, and remote maintenance capabilities, helping production lines achieve more stable in-situ foaming sealing and scalable mass production delivery.

Project Background

On-site project photos

In sealing applications such as in-vehicle electrical control cabinet housings and distribution cabinet door panels, the sealing process is not only related to waterproofing, dust protection, and weather resistance, but also directly affects line takt time, maintenance frequency, and the consistency of mass delivery. Tesla originally adopted a semi-automatic two-component PU foaming sealing process, but during continuous production it faced issues such as material caking inside the equipment, pipeline blockage, and downtime caused by failures, resulting in higher maintenance costs and difficulty in maintaining long-term process stability.

For industrial manufacturing scenarios of this kind that are oriented toward mass production, the sealing solution must simultaneously ensure the protection rating, repeatability, process continuity, and equipment maintainability. Based on this need, WINMAN INDUSTRIAL takes FIPFG in-situ foaming sealing as its core and has built an automated dispensing and sealing process that is better suited to large-scale production.

Key Concerns of Customers

• How to improve dispensing cycle time and production line continuity while ensuring the sealing performance of the door panel and cabinet body.
• How to solve the problems of two-component materials forming lumps inside the equipment and blocking pipelines, which affect stable operation.
• How to achieve online metering and ratio control with dynamic mixing to ensure consistent foamed sealing performance.
• How to improve the consistency and repeatability of sealing paths through high-precision path dispensing and fixture positioning.
• How to support remote maintenance after integration into the production line and reduce production fluctuations caused by downtime.

Solution: Build a fully automatic FIPFG sealing solution with WM601

Addressing Tesla's process challenges, WINMAN INDUSTRIAL, based on its self-developed WM601 two-component PU fully automated dispensing machine and combining it with original German RAKU-PUR® polyurethane sealing material, has developed an integrated FIPFG on-site foaming and sealing solution for automotive electronic control cabinets and door panels. This solution emphasizes simultaneous optimization across four dimensions: material control, trajectory control, pressure protection, and production line collaboration, thereby improving process stability and mass production adaptability.

Implementation Process: From Process Diagnosis to Production Line Integration

1. Requirement research:Address clogging, agglomeration, and downtime issues in the existing semi-automatic process, and define the targets for sealing accuracy, cycle time, and maintenance.
2. Solution Design:Systematically configure around the capabilities of the WM601 equipment to match the characteristics of two-component PU materials and application operating conditions.
3. Equipment commissioning:On-site calibration is carried out for trajectory paths, foaming parameters, and pressure control to ensure stable sealing layer formation.
4. Production line integration:Integrate the dispensing process into the overall line assembly cycle to achieve seamless integration with the production workflow.
5. Training and Support:Provide training for operators and establish a remote maintenance support mechanism to improve daily operating efficiency.

Application Results

After the solution was implemented, the sealing process for Tesla door module panels and related cabinet enclosures achieved more stable performance during continuous production, making the overall production line better suited to the requirements of large-scale mass production.

• Production efficiency increases by approximately 60% after fully automated processes replace semi-automated workflows.
• Process stability is improved, and the defect rate is reduced to within 2%.
• Maintenance frequency and downtime losses are reduced, resulting in an overall cost reduction of approximately 10%.
• Trajectory dispensing and in-situ foaming molding are more consistent, making sealing quality easier to standardize and replicate.
• Remote maintenance and online monitoring improve response speed and support more stable batch delivery.

Case Insights: A Path to Upgrading Sealing Processes for Mass Production

This case shows that in applications such as in-vehicle electrical control cabinets, door panel sealing, and similar industrial enclosures, what truly determines delivery stability is not just the material itself, but whether material control, equipment control, and production line coordination form a closed loop. For manufacturers that need to upgrade from semi-automatic processes to stable mass production, the value of FIPFG in-situ foamed sealing lies in clearer process boundaries, more controllable repeatability, and a standardized production model that is easier to implement.

As a manufacturer specializing in FIPFG dispensing and sealing systems, WINMAN INDUSTRIAL continues to focus on two-component PU foam dispensing, high-precision path control, online metering and mixing ratio control, and production line integration capabilities, providing intelligent sealing solutions better suited to actual production for industries such as automotive lithium batteries, energy storage systems, electrical control cabinets, and photovoltaic equipment.

Applicable Scenario Keywords

FIPFG in-situ foam sealing, two-component PU foam dispensing, Tesla on-board electric control cabinet sealing, door panel sealing and IP protection, high-precision path dispensing automation, dynamic mixing and online metering ratio control, pipeline anti-clogging and anti-caking control, remote maintenance and production line stability, fixture positioning and repeatability control, mass production yield improvement and cost optimization.

Want to upgrade your fully automated sealing production line for automotive electronic control systems?

Say goodbye to material clumping, clogged lines, and the challenges of frequent downtime and maintenance. With mature FIPFG foam sealing technology and the WM601 fully automatic dispensing machine, you can quickly upgrade to automated sealing processes and steadily improve production capacity and product yield.