Chassis Jounce Bumper PU Casting Production Line in China

Illustration notice. Process illustrations are not verified photographs of this installation.

Project reference basis. Figures and configuration details are reported in the supplied project brief. They are reference values for the stated application, rather than verified acceptance results or a guarantee for another installation. Confirm the source records, material, tooling, operating schedule and test method when assessing a comparable project.

Haifeng successfully commissioned a high-precision microcellular polyurethane elastomer casting workcell for a leading Tier-1 automotive suspension manufacturer in China, enabling the mass production of jounce bumpers capable of enduring over 3 million dynamic fatigue cycles. The turnkey project covered the complete delivery of high-temperature vacuum degassing metering machines, dynamic high-shear casting heads, and integrated vertical clamping press interfaces.

Prior to commissioning, the manufacturer relied on third-party suppliers for suspension microcellular buffers. Subcontracted components suffered from micro-porosity defects and batch-to-batch density variations, causing premature cracking during endurance testing on multi-axis road simulation rigs. The customer required an in-house automated production platform capable of maintaining constant chemical vacuum levels, precise precursor heating up to 120°C, and closed-loop stoichiometric ratio locking.

Operational since February 2025 on a continuous two-shift production schedule across a 200 m² footprint, the workcell delivers consistent component repeatability. By implementing Haifeng's closed-loop dynamic casting technology, the client reliably produces microcellular jounce bumpers and suspension mounts that comply with rigorous OEM dynamic stiffness and fatigue endurance requirements.

Concept illustration: The process image is a concept illustration used to explain the equipment arrangement; it does not document the delivered site.

Haifeng deployed a high-temperature elastomer casting architecture engineered for precision microcellular formulations:
1. Continuous Vacuum Degassing: Prepolymers are degassed under negative pressure to completely extract dissolved air, preventing bubble defects in cellular spring walls.
2. High-Precision Thermal Loops: Triple-jacketed stainless steel lines maintain fluid temperatures at 115°C (±0.8°C), preventing prepolymer crystallization.
3. High-Speed Dynamic Mixing: A specialized mixing head operating at up to 6,000 RPM mixes prepolymers with curative agents, delivering laminar void-free pours into vertical heated tooling.
4. Vertical Clamping Synchronization: The master PLC coordinates automated pouring trajectories with vertical multi-cavity press closures, ensuring uniform cell expansion.