AvtoVAZ has mastered the production of front bumpers for the Lada Azimut crossover using the largest mold in the history of the plant's plastic products manufacturing. The weight of the injection mold reached 40 tons. The full cycle of manufacturing one part takes 77 seconds.
The process is fully automated: plastic is heated to over 200 degrees, fed under pressure, cooled, and extracted without human intervention. To fine-tune the technology, about 500 trial bumpers had to be produced before the part met stringent surface quality requirements. Simultaneously, the paint line was modernized – a new program was written for robots and an additional compressed air blowing ramp was integrated.
The bumper arrives at the conveyor not as separate elements, but as a ready-made assembly module weighing up to 18 kg. Lighting, a safe parking system, air flow distribution shields, and decor are already integrated into it. The modular assembly method speeds up the conveyor cycle and improves the quality of the final car.
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