Copyright Alpine Mold Engineering Limited(Alpine Mold) All rights reserved.
2023-02-15
Mold Making Process: CNC machining, Mirro EDM, wire cutting Part Making Process: Plastic Injection Molding Mold Material: 718H Steel Part Materials: Chemical Resistance ABS |  |
 | This client is from the United States. Professional research and development of various sensors for smart home, atmospheric environment, fire protection, public health, petrochemical, etc. The projects that customers come to us for are mainly electrochemical sensors, so the requirements for plastic materials are quite special. |
The customer needs us to complete this sensor housing according to their product design, which is specially used to detect the concentration of ambient gas. To ensure they receive a high-quality product, we must meet the following design and engineering specifications:
After receiving the customer's drawing, our engineers will evaluate the drawing and make a detailed DFM report, pointing out the product's injection gate, wall thickness, etc., and will provide professional advice.
Wall Thickness
The use of good design practices for wall thickness and related properties has always been a concern in plastic injection molding. This is because molten resin distributes heat throughout the molded part, but areas with uneven heat distribution will cool at different rates. This is one of the main causes of dents and other potential defects.
When customer confirmed DFM report, our engineers will do mold design. This product is small and production volume is large, so we suggest customers make 4 cavities to save costs. After mold design was finished, we will start to make the mold. At the same time, we will send weekly report to let customer know the project progress.
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This is a relatively precise sensor plastic accessories, it has a relatively high requirement for size stability.
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Challenges: Tolerances of ±0.02mm are required for most product components.
Reason: Only the precision standard can make its air tightness, waterproof is guaranteed, the electronic components and liquid inside will not be affected by the outside world.
Solution: In the process of injection molding, the size of plastic parts depends on many variables. The factors that affect the size of plastic parts including material, performance, design, machine and production process.
When the first batch of samples are produced, we have our own quality inspection department, which will check the size, appearance, injection gate and so on. At the same time, we have advanced testing equipment Zeiss CMM testing machine to accurately measure the size of products.
One of the most important decisions to make before manufacturing a product is to choose the right material for the job.
This product is an electrochemical sensor, and the base of the product needs to touch the circuit board, so we choose ABS material with chemical resistance. It has good chemical resistance to environmental stress cracking, and can be dissolved in chemical solvents for ABS.
Ultrasonic welding is an industrial process whereby high-frequency ultrasonic acoustic vibrations are locally applied to work pieces being held together under pressure to create a solid-state weld. It is commonly used for plastics and metals, and especially for joining dissimilar materials.
We use ultrasonic machine to weld the copper foot on the base of the product, in order to prevent powder or chemical liquid leakage inside the sensor.
This is a great example of different products that are used in different environment, we should choose the corresponding mold steel and plastic materials. We've also done different types of projects, fire-resistant materials, UV resistant materials and so on. We love the challenge and look forward to the next one!
Read about other great project, contact our team with your latest project design for manufacturing review for free quotes and designs.
Copyright Alpine Mold Engineering Limited(Alpine Mold) All rights reserved.