PC Electrical Appliance Radiator Housing Injection Molding Manufacturer

2024-08-10



Manufacturing Service: Injection Mold Design,  Plastic Injection Molding Service

Plastic Material: Fireproof PC

Mold Steel: S136

Runner System: Hot runner

Mold Surface: Texture - VDI 27






About this project



This project is a high-end radiator housing for electrical appliances, which is made of fireproof PC material, with its large size, porous design and special requirements on surface texture, it becomes a big challenge in mold design and injection production. At the same time, the back part of the product needs to be assembled with some light guide pillars, which requires very high precision of the product.





Project Challenges and Solutions



1. Injection molding defects - Weld line


Challenge: Due to the large size of the product and the dense surface of small holes, the injection molding process is prone to weld line defects, which affects the product appearance and performance.



Solution: 1) In the early stage of the project, we deeply analysed the product structure characteristics and formulated a detailed DFM report and mold flow analysis to predict and avoid potential injection defects in advance. By optimizing the mold structure, such as adopting 2 hot tip direct on part and optimizing the cooling system, we have effectively reduced the generation of weld lines.




hot tip direct on part
Weld line




2) At the same time, in close communication with the customer, it was decided to do a rough texture treatment on the mold surface, which can hide the subtle injection marks and enhance the overall aesthetics of the product.





3) 20+ Experienced injection molding tuning masters provide the solution. To ensure the smooth injection molding process, we are equipped with a team of experienced injection molding tuning masters. They are able to quickly identify and adjust the injection parameters, such as temperature, pressure, speed, etc., according to the actual situation on site, in order to cope with various injection defects that may occur. For other possible injection molding problems, such as shrinkage, bubbles, etc., we have also made a detailed emergency plan to ensure that the problems can be solved in time.








2. Mold material selection and processing



Challenge: Considering the particularity of the product material (fireproof and UV resistant), the mold material needs to have good hardness, corrosion resistance and wear resistance.


Solution: We strongly recommended S136 mold steel to our customer, which is ideal for processing this kind of demanding products due to its excellent corrosion resistance, high polishability and good thermal stability. During the mold manufacturing process, we adopted a heat treatment process to harden the S136 steel to ensure its stable performance in use.





3. High precision mold processing


The product needs to be installed with many light guide pillars inside, which puts high demands on the precision of the mold.




Solution: In order to meet this demand, we are equipped with high-precision processing equipment, such as FANUC CNC, Charmilles EDM machine, slow wire cutting machine, etc., to carry out fine processing of molds. Through strict processing control and precise inspection process, we ensure that all parts of the mold can achieve extremely high dimensional accuracy and surface quality, which provides a strong guarantee for the smooth assembly and excellent performance of the product.




Mold CavityMold Core


Project Achievements



Alpine mold, as an expert in the mold industry, our team, with 22 years of technical accumulation and 10,000+ projects experience, successfully overcame the technical problems of this project, and ensured the high quality of the product for injection molding production.






Conclusion


In the future, we will continue to uphold the concept of "striving for perfection and pursuing excellence" to provide customers with more high-quality and efficient mold solutions.