The Customer: A manufacturer in the motorcycle industry sought to enhance the design of their motorcycle steering wheels. They required a solution that was not only effective but also cost-efficient.
The Challenge: The primary challenge was to develop a steering wheel component that could integrate electronic and mechanical elements effectively. Traditional connectors, which join the interface of two electronics – flex to Printed Circuit Board Assembly (PCBA), were costly and less efficient for their needs.
The PICA Solution: In 2018, PICA embarked on a project to address this challenge. Their solution was a revolutionary design that combined Flexible Flat Cable (FFC), PCB, Metal Pin, and Plastic Overmold post Surface Mount Technology (SMT). This design utilized extended copper conductors from the flex, a method more economical than conventional connectors.
The innovative approach included:
- Connecting FFC and PCB using hot bar technology.
- Attaching pins to the PCB through SMT technology.
- Transforming pins and FFC into connectors via overmold technology.
This method eliminated the need for additional insertion processes, making the design more reliable.
The Result: PICA’s solution not only met but exceeded the customer’s requirements by offering a low-cost and highly efficient alternative for interconnect challenges. The integration of various technologies led to a more reliable product, reducing the number of components and simplifying the assembly process. This project showcased PICA’s ability to leverage its engineering expertise to create tailored, innovative solutions that address specific client needs while setting new industry standards in product design and manufacturing.