Exchange Blow Molding

Exchange® Blow Molding

Great Reduction in Parts and Costs

Exchange Blow Molding is the technology to integrate materials with different nature (such as soft material and hard material) in one operation by Blow Molding.

Main body is from hard material with rigidity, bellows and inserted part are from flexible soft material. The parts which have traditionally been formed from metal and rubber are resinified and integrated by Blow Molding.

By adopting this technology, great reduction in parts and in costs has become possible.

Basic Concept of EXCHANGE®

Bellows and inserted parts are formed in soft material. The rigid main duct is formed in hard material. Sharp material transitions are applied to keep the original design intent for hard and soft material.
This makes multiple exchanges of materials possible and allows us to provide products with excellent functionality.

Basic Concept of EXCHANGE

Example of Turbo Air Intake Duct

Forming Multi-dimensional Products without Barr

Below is an example of a Turbo Intake Duct. A metal duct is used as a main part. A rubber hose at both ends is resinified with nylon.

Metal duct is resinified with hard material using MES, with rubber hoses at both ends being integrated by the Exchange Blow Molding process.
Significant cost reduction has been achieved, along with a reduction in weight.

Traditional(metal+rubber) / MES(PA6GF30% + rubber) / MES-EXCHANGE(PA6GF30% + PA11)
Example of Turbo Air Intake Duct
Weight Reduction; 40% and Assembly Process; 1/3

Application of EXCHANGE® (Air Flow Duct)

Below is an example of an Air Flow Duct comprised of an aluminum duct and rubber hose that are integrated by Exchange Blow Molding.
Metal aluminum part is changed to hard polypropylene resin. The rubber hose is changed to soft thermoplastic olefin.

Traditional (Aluminum Duct + Rubber Hose) / EXCHANGE Blow Duct (PP + TPO)
Weight Reduction 50% and Assembly Process 1/2

Comparison between Traditional Process and EXCHANGE® Process

Traditional rubber and metal construction design is changed to blow molding.
This allows a significant reduction in components, assembly price, and weight, while increasing the sealing characteristics of the duct.

Traditional / MES-EXCHANGE
Parts Saving; 70% and Assembly Process 67%
Parts Name Traditional Pipe MES-EXCHANGE PIPE
Part Ass'y Part Ass'y
Total 23 pcs 24 prcs 7 pcs 8 prcs
Pipe 2 4 1 2
Rubber 3 2 0 0
Hose Band 6 6 2 2
Washer 6 6 2 2
Bolt 6 6 2 2