Injection molded plastic housing for FLIR

By Frances Ganz | Feb 20, 2020
FLIR's injection molded housing and electroform logo

FLIR, a global leader in thermal imaging camera systems, had developed a line of fixed-mount thermal marine cameras with a protective metal housing.  However, their existing housing was not only heavy but also expensive and time-consuming to manufacture. Looking to re-design the metallic housing, FLIR approached GM Nameplate (GMN) for an alternative solution.  

As the housing remains an integral part of the thermal camera system, it would be repeatedly exposed to challenging surroundings including ultraviolet rays, seawater, and high winds. Keeping the severe outdoor conditions in mind, GMN proposed to replace the metal housing with a robust, industrial-grade plastic that can endure prolonged marine use and environmental damage. Additionally, plastic is not only cost-effective but also seven times lighter than metal and faster to fabricate. The housing was fabricated via injection molding at GMN’s Beaverton, OR division.    

FLIR’s original design also comprised of a chrome-plated logo attached to the metal housing with hooks. The hooks were attached to the metal via heat staking, a process of melting metal to create a bond. However, the seal formed via heat staking was not airtight, causing unwanted water to seep through the crevices and gradually oxidizing the metal hooks and housing. To resolve this sealing issue, GMN switched the original chrome-plated logo with a 3D electroform logo. This unique metal decoration technique deposited nickel and chrome directly on the desired form to create a high-quality, corrosion-resistant, three-dimensional logo. The distinct logo was brought to life at GMN’s Monroe, NC division and adhered to the plastic housing with a pressure-sensitive adhesive. Offering extremely high durability and visual appeal, the finished product flawlessly married plastic with metal.  

GMN brought together two of its core capabilities and manufacturing locations (metal decoration at Monroe, NC and plastic injection molding at Beaverton, OR) to effectively meet the needs of the program. Following the successful completion of this project, FLIR returned to GMN to develop both a smaller and larger housing for a similar camera line. 

To learn more about plastic decorating capabilities and value-added assemblies, visit our website here.