ABB’s New SAGA™ Wiring Accessories with High-Quality and Safe Injection Molds

Safety and Quality Through Consultation 

The goal of the collaboration was to ensure that the sustainable and responsible series is also manufactured according to the same values. Careful quality assurance ensures not only a sustainable, but also resource-efficient and uninterrupted production. By identifying design errors and optimization needs for products early, before mold production begins, significant savings can be made in both production and natural resources.  

Steel injection molds weighing several tens or even hundreds of kilograms consist of hundreds of small parts. Every little part is an important piece of the whole that must work in harmony. Therefore, during the DFM (Design for Manufacturing) phase of the molds, the parts and details were examined carefully. Eventually, as the iterations progressed, the molds evolved towards their finished form. 

In accordance with The ABB Way, occupational safety is a top priority in all operations. The molds were designed in such a way that they are safe not only to use, but also to maintain. Therefore, the positioning of parts and connectors was precisely defined to ensure safety and minimize risks. For example, mold users must be able to safely lift heavy moulds in case of maintenance or mold change. Proper balancing, support and adequate attachment ensured that they would not fall or tilt when lifted. 

Environmentally Sustainable Product Design 

The SAGA™ series is mainly made of ISCC PLUS certified bio-based plastic, which is also suitable for recycling. 

In addition, the molds were mainly designed using hot runner systems, while minimizing the use of runner systems. This minimizes excess material usage and maximizes the process window by increasing the ability to adjust various parameters. According to ABB, the use of bio-based materials will reduce climate emissions by 400 tonnes of CO2 equivalent annually by 2030. 

“We needed more capacity for formwork design, as our own resources were not enough for such a large project. Huld’s design experience was exactly what we needed – solid expertise in mold design and injection molding. The scalability of the workload was implemented well, even though the duration of the project was long by our standards.” –Jonathan Ewalds, Production Development Specialist, ABB Oy, Wiring Accessories

SAGA™ Series on the Market 

ABB and Huld’s collaboration consisted of professionals from many different fields, who complemented each other in terms of background and experience. As a result of the collaboration, injection molds for the SAGA™ series meet the requirements in terms of quality, safety and durability. The series made with the designed molds can already be found in stores. 

“I’ve been in different roles in the plastics industry for almost 30 years, and yet I’m still learning new things (and applying my own experiences to others). It was pleasant and efficient to work with the experienced professionals in ABB’s team. The project was diverse, and our team worked well together. We were able to utilise the core competencies of all participants, and together with ABB we built something bigger than we could have done as individuals.” – Lasse Kettunen, Senior Mechanical Design Specialist, Huld.