• Achieving precise \pm 0.05 mm tolerance in plastic molding requires meticulous control over both tooling and process:

  • Mold Compensation: Our engineers use advanced simulation software (Moldflow) to accurately predict and compensate for the specific shrinkage rate (par exemple., abdos contre. PC) within the mold design. The cavity is intentionally oversized based on the polymer to achieve the net required dimension after cooling.

  • Contrôle des processus: We strictly monitor injection pressure, holding time, and cooling temperature during the production cycle. Consistency in these parameters is vital because any variation can alter the material’s crystalline structure, directly impacting final part dimensions and warpage.

• The choice depends on production volume and budget:

  • Multi-Cavity: Advised for volume élevé production (par exemple., hundreds of thousands of units). The primary advantage is significantly lower cost-per-part et faster cycle times. The trade-off is a higher initial tooling cost and slightly more complex maintenance, as all cavities must produce identical parts.

  • Single-Cavity: Mieux pour prototypage, à faible volume production, or when making very large components. It features a lower initial tooling cost and is easier to modify or maintain, but the cost per part is higher.

Both processes combine different materials into one part, Mais leurs fonctions diffèrent:

• Moulage par insertion: Involves placing a pre-formed non-plastic component (usually a metal thread, shaft, or electronic pin) into the mold, and then injecting the plastic around it. Application: Creating durable parts with strong metal threading (par exemple., brass inserts in electronics housings).

• Surmoulage: Involves molding a second, softer layer of plastic (par exemple., TPE ou TPU) onto a previously molded, rigid plastic part. Application: Creating ergonomic soft-grip handles, sealed gaskets, or enhancing the tactile feel of consumer goods.

These materials are chosen because they possess superior properties essential for mission-critical and sterile environments:

• COUP D'OEIL (Polyether Ether Ketone): Chosen for its exceptional résistance chimique (including resistance to harsh sterilization chemicals) and ability to withstand continuous high operating temperatures.

• Î.-P.-É. (Ultem): Chosen for its inherent flame retardancy, rapport résistance/poids élevé, and excellent dielectric properties (electrical insulation), making it ideal for aviation components and medical device enclosures. Their performance ensures safety and longevity where standard plastics would fail.

Controlling cosmetic defects is integrated into the mold design and process setup:

• Marques d'évier & Warpage: Controlled by optimizing gate location (placement where plastic enters the mold), wall thickness uniformity (reducing thick sections), and precisely managing the holding pressure et cooling time to ensure the core of the part solidifies properly.

• Éclair: Controlled by ensuring the mold halves are perfectly aligned and clamped with sufficient tonnage to withstand the injection pressure.

• Lignes de soudure: Minimized by increasing the melt temperature et injection speed to help the plastic flow fronts fuse more completely, though their placement is often managed by designing the gate to place them in non-visible or non-critical areas.