Productassemblageservice in China

Finding reliable assembly companies near me can be quite challenging. In a competitive environment, distinguishing between quality providers and inferior ones is a quite complex task. If you are looking for the leading assembly companies near your locality, it’s now imperative to exercise your choices wisely.

In addition, while searching for a product assembly company near me, it’s better to pay attention to specialized firms nearby. The electronic, medical, and cable assembly companies are suitable to meet the various demands. Check up on their capabilities, and client feedback to see if they are fitting for your project at hand.

It will also assist you in identifying the most suitable partner and improving on efficiency and quality of the assembled elements. Curious to find a reliable assembly company near me? This article will consider assembly firms with high profiles in China, Europe, and the United States. Learn about the individuality of each company and how you can address your assembly requirements to them. Let’s dive in!

When you are looking for products assembly services, I assume that you are also looking for plastic injection molding compnies near me as your location, in that case Sincere Tech will be one of your best options.

assembly company near me

List of Top 12 Assembly Companies In The World

Table: Top 12 assembly companies in the world.

Company Name Locatie Year Founded Employee Size
Supex Machining China 2013 10-12
Sincere Tech (All in one services) China 2005 51-200
PCBway China 2014 501 – 5k
Hi-Tech Circuits China 1997 501 – 5k
RayMing China 2012 501-1,000
JLCPCB China 2006 1k – 5k
Benchmark Electronics US 1979 11-50
Kimball Electronics US 1961 5k – 10k
Celestica Canada 1994 10k+
MedTech Innovations UK 2016 51-200
Xinfeng Cable China 2017 501 – 1k
Viant US 1999 201 – 500

1. Supex Machining

SUPEX was established in 1974 in Shenzhen, China. The company offers diverse solutions for assembling products such as mechanical, electromechanical as well as cable harness assembly. This gives them valuable insights for executing projects. As a result, they can optimize work in sectors such as the automotive, aircraft manufacturing, and equipment-making industries.

SUPEX provides solutions for automobiles such as connecting rods, gearboxes, fixtures, and cable assemblies. Besides, the fixed structure and precise temporary assembly structures are provided for by the facility and all their parts undergo rigorous quality tests, before end-use. They employ ISO 9001 compliance in their processes reflecting a strategic focus on the ideals of quality and reliability. In its bid to produce high-quality work, it carries out inspections that include standards inspection and checks as well as dimensional reports.

Moreover, they give their valued customers First Article Inspection Reports (FAIR AS9102) to meet the legal requirements in the market. Incorporating superior technologies and a network of accredited partners, SUPEX provides excellent assembly services as well as supply chain services.

2. Sincere Tech

assembly company near me Dongguan Sincere Tech Co., Ltd. offers a comprehensive products assembly services in China with extensive capacity and technical expertise. Their premium assembly services cover electronics board assembly, plastic components, PC boards, and packing products. They make use of ultrasonic welding, heat welding, and PCB soldering among other techniques to accurately curate high-standard assembly products.

Sincere Tech has over decades of experience in the industry and the company adopts advanced technology to enhance their manufacturing capability. For instance, Sincere Tech takes pride in providing small-scale prototypes to mass-scale products in a short turnaround. Sincere Tech has in-house facilities for all in one services from the part and PCB design, prototyping, testing, mold design and manufacturing, injection molding manufacturing, die casting products, metal stamping, machining, certificate, and assembly.

They also provide comprehensive and precise assembly and packing before shipment. Thus, by keeping the dependence on the purchased parts and components affordable, Sincere Tech has better control over the production schedules and quality typically inherent to the Chinese OEM contract manufacturing ethos.

3. PCBWay

PCBWay was started in 2014, as an organization based in China. They are specialized in the fabrication of printed circuit boards and circuit assemblies. Moreover, the company provides a diversified list of assembly services targeting the electronics industry, a prominent sector among their lists. The core services offered by PCBway include Prototype PCB assembly, SMT assembly, BGA assembly, and mixed assembly.

They work on different forms of projects such as cable and box build assemblies too. PCBway can turn around quick, high-quality assemblies in about 3-5 days, which would position them to handle both low to mid-volume manufacturing requirements. Their quality control measures uphold IPC 610 Class 2 and Class 3 which give reliability and accuracy to their all products.

In addition, they employ automated optical inspection (AOI) and X-ray inspection in the manufacturing technologies used to ensure high-quality assembly at their in-line setup. These advantages make PCBway a preferred partner for electronic manufacturing because of their willingness to satisfy their client’s needs and short-time deliveries.

4. HiTech Circuits

HiTech Circuits is a PCB fabrication and assembly company located in China. It has grown to become a major player in the electronics manufacturing solutions industry. The company offers a range of specific services, including prototype PCB assembly, automated assembly, wave soldering, selective soldering, and point-to-point wiring. These are just a few examples of their capabilities.

Moreover, they are capable of taking on different production projects– from a very low to a high volume –, which provides versatility for all clients. Standard-quality assemblies are typically completed within a few days, as the company prioritizes a fast turnaround time. Thanks to their high-efficiency machines, allow them to fulfill both prototype projects and mid-volume manufacturing demands successfully.

HiTech Circuits maintains high standards, conducting visual inspections along with automated optical inspections (AOI) and X-ray inspections to ensure stringent set quality. With quality assurance measures and a deep orientation to customers’ services, HiTech Circuit has established itself as a trustworthy ally to organizations looking for precise electronic assembly services.

5. RayMing Technology Co., Ltd.

RayMing Technology Co., Ltd. is a specialized manufacturer and supplier of high-frequency PCBs established in the year 2005 located in Shenzhen, Guangdong, China. It positions itself as a responsible participant in the electronics manufacturing market. Several categories of products constitute RayMing’s service portfolio including printed circuit board manufacturing, PCB assembly, box-build assembly, parts purchasing, and PCBA testing.

Their production methodology is elaborate and involves sophisticated technology and quality materials that enable the firm to fulfill the unique electronics market demands. Maintaining high quality is a key goal for management at RayMing. They achieve this through advanced quality management systems like ISO 9001 and QS 9000. These systems are complemented with specialized inspection equipment so that the products can be carefully inspected throughout production.

Additionally, RayMing is a standard PCB assembly company that offers IC programming services. This allows them to program integrated circuits on PCBs to meet client needs. This capability increases their offerings to clients as it can serve to prototype as well as produce finished products. With a small team of 1 to 10 employees, the organization is more focused on customer orientation.

They ensure that employee initiatives exceed client expectations. This is achieved through constant improvement of the client’s value propositions. So, overall, RayMing can be distinguished as a reliable partner offering PCB solutions and using accountable technologies and quality control to supply higher-worth offers within the global market.

6. JLCPCB

JLCPCB was established in 2006 in China. It has made giant strides and grown to be among the best suppliers of PCB manufacturing and assembly services. The company is reputed for its professional swift service delivery methods and shorter turnaround periods which provide a full range of precise service solutions aimed at satisfying the electronics sector.

JLCPCB deals with all forms of PCBs, rigid PCBs; flex PCBs; and high-frequency PCBs. Their manufacturing process can handle up to 32 layers which makes it suitable for sophisticated designs as well as designs, that need specific control impedance. The company uses FR-4 laminates for their superior quality, sourcing them from reputable manufacturers. Additionally, they offer PCBs with aluminum and copper cores for specific applications.

In addition,  JLCPCB has flexibility in dimensions, the maximum size for 2-layer FR4 boards can be 1020 × 600 mm. The company also ensures accurate specifications in its operations with manufacturing tolerances fixed at ± 0.1mm for key part sizes. Quality assurance is a central concern of JLCPCB. The firm uses several methods such as AOI and X-ray inspection.

For such reason, JLCPCB has become a go-to supplier for electronics manufacturing companies. Besides PCB fabrication, JLCPCB provides one-stop PCB assembly solutions, SMT, and TAH to meet low and middle production requirements. Moreover, they include such value-added services as parts sourcing, IC programming as well as box-build assembly for the development of electronics products.

Thanks to online orders, JLCPCB’s service provides customers with an opportunity to upload designs and get quotes within minutes. Due to their focus on customer satisfaction embedded with quality services, they are considered to be among the best manufacturing industries for electronic assemblies.

7. Benchmark Electronics

Benchmark Electronics is a dominant and largest contract manufacturer of electronic assembly. It targets the higher end and more specialized electronics goods; as a result, it applies sophisticated SMT to guarantee precise assembly components. At their platform, Every PCB is closely monitored and examined by incorporating optical, laser, and even X-ray technologies to assure component traceability and compliance with high regulatory requirements.

The company has an extensive service portfolio of SMT Assembly, BGA packaging, COB, MCM Assembly, & PTH Assembly with automated SMT Assembly at a very high complexity. This kind of diversity puts Benchmark in a position to meet different electronic manufacturing needs with high performance and reliability. Benchmark brings together innovative technology and engineering design services with an efficient supply chain structure to provide exceptional manufacturing services to fulfill clients’ requirements. Thus, the company is well-placed to be a preferred player in the electronics assembly manufacturing settings.

8. Kimball Electronics

Kimball Electronics is a leading global supplier of electronic manufacturing services offering high-reliability PCB assembly and other value-added products. The company conveniently offers solutions that meet the high requirements of industries like medical, automotive, and industrial electronics. Their commitment to quality makes them suitable partners for businesses that deal with high-relativity product needs.

One of the main competencies of Kimball is complete manufacturing solutions that involve engineering, design, and production. This process improves manufacturability and ensures a smooth transition from design for manufacturing to full production. The company also provides fast prototyping for the prototype development in a short time to make changes faster.

In addition to the capabilities of Kimbel; the company applies Surface Mount Technology (SMT), Ball Grid Array (BGA) packaging, and Chip-on-Board (COB) technologiesbring product assemblies to final use. Moreover, they enable undertaking through-hole and Multi-Chip Module (MCM) assembly to address the challenges of the current electronics. This diverse experience makes it possible for Kimball to meet different assembly needs. Quality is a core value at Kimball Electronics.

The company’s assembly accessories are compliant with standards such as ISO 9001 and ISO 13485. Furthermore, they use optical, laser, and X-ray tests to ensure product reliability and conformity to market standards. In addition to assembly, Kimball Electronics offers a wide range of aftermarket support services to meet modern market requirements. The focus on the customer’s solutions helps to create strong and stable relationships by signifying their satisfaction level.

9. Celestica

Precision manufacturing, and product assembly solutions position Celestica as a premier leader in the contemporary market. Celestica uses state-of-the-art technology in line with industry knowledge and enables complicated electronic products. These advanced systems lead to higher effectiveness and flexibility.

Clients from various industries rely on Celestica for their highly repeatable, and reliable services. Aerospace, healthcare, and industrial equipment industries are heavy consumers of Celestics products that benefit immensely. The company has its specialization in multi-material assembly that includes aluminum, stainless steel, and much more.

Effective electro-mechanical assembly ability guarantees the quality performance of every project. Moreover, their automated systems can effectively work 24/7, thereby giving the highest levels of productivity and minimum to zero downtime.

Celestica’s commitment to quality ensures that the company delivers the expected outcomes. Moreover, they work hand in hand with the clients to develop solutions that address certain requirements. The close collaboration with the partners allows for using creativity to address manufacturing issues. It puts them on a better pedestal in the global market and makes them a strategic partner

10. MedTech Innovations

MedTech Innovations is based in Oulu, Finland. It has a wide global network, and branches in Germany, UK, and Ireland. The company is dedicated to offering sophisticated assembly solutions that apply specifically to the medical technology industry. Some of its principal products are the integration of wireless medical instruments, power-sensitive devices, and other related healthcare systems.

The biggest advantage to partnering with MedTech Innovations is their dedication to quality assurance. The company is ISO 13485 accredited for medical device assembly and all processes have to conform to medical device assembly standards like FDA. This certification shows MedTech’s commitment to quality and thorough product testing.

MedTech Innovations employs sophisticated testing facilities in-house and offers mechanical, environmental, and RF testing. This capability improves product quality and safety and makes the firm unique from other assembly firms in the market. Furthermore, flexibility characterizes the assembly processes allowing MedTech fast reactions to market needs and the development of personalized solutions for clients.

Being located in a strategic place, devoted to the quality of offering innovative assembly solutions, MedTech Innovations offers the highest quality of medical technology products to meet its clients’ needs for a reliable partnership. So, if you’re searching for medical assembly companies near me, you can visit MedTech to get personalized solutions.

11. Xinfeng Cable

Xinfeng Cable was founded in 1996, located in Zhengzhou City, China. The company offers a wide variety of cable assembly solutions such as aerial bundled cables, control cables, and medium and low-voltage cables. As an innovative and quality-oriented company,

Xinfeng Cable works in partnership with contractors and consultants to provide optimal cables for specific purposes. As for quality control, Xinfeng Cable follows international standards such as IEC, VDE, and UL. The company also offers versatility in customizations, allowing it to meet the needs of a certain project as required.

In addition, their production plants and equipment are well-outfitted to provide efficiency, high-capacity output, and quality production. The company has rich experience in many sectors such as power networks, construction, renewable energy, and several others. For clients searching for local cable assembly companies near me, Xinfeng Cable’s diverse capabilities and strong reputation make it a popular choice.

The commitment to provide quality client support coupled with appropriate supply chain management and after-sales service is an added benefit of Xinfeng cable in the market. Regardless of your requirements for standard cables or special solutions, Xinfeng Cable is prepared to help with all assembly requirements.

12. Viant

Viant was founded more than three decades ago. Being a certified contract manufacturing company that offers safe products to the medical sector. Viant currently has facilities in the United States and Europe, as well as in countries such as China, Costa Rica, Mexico, and Puerto Rico, which make it possible for it to expand its operations.

Moreover, the company has the ISO 13485 and 14971 certifications, which makes it possible to produce both Class I, II, and III devices. Viant has clean and white room facilities offering a controlled environment with Class 7 and 8 medical device assembly. The manufacturing capabilities of Viant range from low-volume prototyping to high-volume production to allow for changes in the demand of clients. Their competently developed Lean Six Sigma program improves productivity and process quality. The firm possesses assembly skills, both manual as well as automated with the use of ultrasonic welding, RF welding, and precise measurement tests.

In addition to capabilities, Viant features specialization action in Sterile Barrier Packaging and capable of managing challenges related to Medical Technology assembly. They have a strong supply chain and sourcing. This approach reduces the likelihood and difficulties linked to switching from one manufacturer to another as scaling occurs. Thus, clients who choose Viant as their outsourcing partner get more than an extensive list of assembly services, strict quality control, and a focus on developing unique solutions for the medical field.

How To Select the Right Electronic Product Assembly Partner For Your Project?

When selecting an assembly company near me as a partner, consider these unique points:

  • Specialization in Industry Standards: When seeking product assembly partners, make sure that they meet certain standards such as IPC or ISO.
  • Advanced Technology Integration: Select a partner who is implementing state of art technologies which include included assembly, AI-based control, or real-timeless to boost production line productivity and quality.
  • Flexible Scalability: It’s also suggested to assess the skill of the partners for changing the production capacity as per the requirement so that the inventory level and lead time can be handled properly.
  • Prototyping and Iteration Support: The manufacturers who can deliver rapid prototyping and design iterations can shave weeks or even days off the project schedule and bring changes that result from testing.
  • Local vs. Global Manufacturing Options: Consider the benefits of having a local assembly for quicker turnaround and better communication. Compare this to using global facilities for cost savings and increased scalability.
  • End-to-End Supply Chain Management: Choose a partner who can supply and manage the entire supply chain as well as procure and manage part components, and transportation.

Samenvatting

In summary, the choice of the contract electronics assembly firm plays a major role in the success or failure of your projects. So, having a strategic alliance with those who are most proficient in SMT manufacturing, engineering services, and supply chain management is a sound starting point. It also means that it solves problems during production and at various stages of the product lifecycle.

Potential EMS partners should be carefully assessed by considering their capacity experience, and corporate philosophy. Procedures of the communication and business models also have to match your goals for the partnership to be effective in the long run.

Based on the profiles of a leading electronic assembly company near me. Take a step further in your search for service providers that would meet your requirements. If you have a reliable and experienced partner, you can minimize the time and effort needed to provide your consumers with the best innovative assembly products.

Veelgestelde vragen

Q1. What should I expect from an EMS partner?

When considering an assembly partner, ensure, they are certified with ISO 9001 and ISO 13485. They also need to have experience in your specific market.

Q2. How does supply chain management influence the efficiency of the production process?

Supply chain management is all about the timely acquisition of components. It eliminates the lead time and therefore, has a direct impact on efficiency.

Q3. Why is quality assurance important in electronics productassemblage?

Quality control check reduces defects throughout the production process to comply with standard measures and customer requirements. This improves dependability and minimizes the cost of recollects and reprocessing.

Q4. What common challenges do manufacturing engineers face in the design phase?

Manufacturing engineering offers significant information during the design process to enhance manufacturability and performance and to identify potential problems before the manufacturing process starts.

Plastic verpakkingen op maat

Custom Plastic containers are designed for individual uses in different industries and sectors. Using high-end polymers, these containers provide improved strength and resistance to chemicals. Custom designs provide specific sizes to fit the items well and also to aid in easy storage and transport. Some of these features include tamper-evident seals and stackability that will allow you to save space. Custom options can be chosen to meet the requirements of regulations and to be environmentally friendly.

Industries Uses Custom Plastic Containers

Various industries use custom plastic containers with lids as they all have different properties. In the food sector, they are approved by the Food and Drugs Administration hence a safe means of containing and transporting perishable foods. Benefits such as hermetic closures and UV protection serve both to enhance the product’s shelf life and to guard it against spoilage. go to food grade plastic material to know more about safeety of products.

In the pharmaceutical industry, custom containers help meet several regulatory requirements to protect the drugs from the environment. Such containers may have child-proof caps and desiccant chambers to ensure the efficacy of the product.

The automotive industry uses end-to-end custom containers plastic to meet its parts management needs. Many of these solutions have components that can be stacked and arranged in a way that would reduce the chance of damage while in transit.

Manufacturers of electronics use their containers that are also static-proof made from plastics. Foam inserts can be custom-designed to improve part retention so that sensitive parts are not harmed when delivered.

In e-commerce, custom containers improve the appearance of the brand and, at the same time, offer sturdy protection to various products. These solutions often involve adding elements that would show if somebody has tampered with the packaging and using sustainable material.

Custom plastic Container manufacturers

Designing Custom Plastic Packaging: Factors To Consider

Designing custom plastic packaging involves a thorough analysis of several technical characteristics:

  • Material Properties: The choice of the proper polymer is of great importance. For instance, the properties of PET (Polyethylene Terephthalate) reveal higher barrier properties of moisture and oxygen than the food products. On the other hand, HDPE (High-Density Polyethylene) gives rigidity and shockproofing and is recommended for industrial use.
  • Dimensional Specifications: One has to be very careful with dimensions to fit the packaging perfectly to the product. Applying CAD software can ease the process of the design and even enable creating tests on various conditions, including stacking and transport stresses.
  • Barrier Functionality: It is crucial to evaluate the degree of required barrier properties. Flexible films can be developed to provide improved shielding from the factors of the external environment. For instance, the interconnecting of EVOH layers is essential in enhancing the reduction of oxygen permeability which is important in the extension of the shelf life of some sensitive products.
  • Mechanical Features: Stress analysis conducted before the manufacturing process allows evaluation of the packaging’s ability to withstand deformation. Applying finite element analysis (FEA) can forecast the failure regions under load so that it is resilient enough during distribution.
  • Sustainability Considerations: Specifically, bioplastics, or any work material and components containing recycled content, will help to reduce impacts on the environment. Assess the final disposal solutions for the packaging, that should correspond to the circular economy model, as well as be effective.
  • Aesthetic Design and Branding: Digital or flexographic printing technologies are used to deliver high-quality graphics that give the brand better visibility. Think about the feeling and the look which may become some factors affecting the consumer’s decision process.
  • Functional Design Elements: Add-ons such as child-proofing or handles as part of the cap design present major challenges at the engineering level. These elements must be made for usability tests and safety standards to follow the industry’s standards.
  • Regulatory Standards: Carefully check compliance with the US FDA regulations for food contact materials, or ISO 9001/2000 regulations for medication packaging. This includes the testing for migration levels and the testing for labeling requirements.
  • Cost Optimization: It is recommended to carry out a cost-benefit analysis at the design stage. This entails the assessment of material costs, manufacturing processes such as injection molding over blow molding, and probable savings on transportation resulting from optimizing the dimensions of the packaging.
  • Manufacturing Feasibility: Consult the manufacturers as soon as possible in the design phase so that the packaging can be made effectively. Evaluate the tooling needed to be completed and the manufacturing schedule so that the project is not slowed down when it is being produced.

Available Sizes For Custom Plastic Containers

Most plastic containers can be made to fit different sizes that can suit different industry types. Here’s a detailed look at common sizes and their applications:

Small Containers (100-500 mL):

These tiny tubs are perfect for portioned products or as a way to allow customers to try your products. Cosmetics employ them for lotions or creams while food industries use them in packaging sauces or dressings. This makes them easy to handle and store, factors that consumers who want easy-to-handle and portioned products consider.

Medium Containers (500 mL – 2 L):

The middle-sized containers are ideal packaging for all kinds of products. It is normally applied to household articles including cleaning products or washing commodities for example shampoos. This size is optimal in terms of capacity and at the same time not too big to be managed for retail sales and at the same time large enough to accommodate bulk sales.

Large Containers (2 L – 10 L):

There is always a need for extended packaging, and large containers are often used to meet these requirements. They find their application in food industries for the storage of food products like oils or marinades, storage of industrial chemicals, and cleaning solutions. They are useful when it comes to an operation that needs large quantities for storage and ease of transportation.

Extra-Large Containers (10 L and above):

Extra-large containers are intended for the industrial segment because they are designed for intensive use. This type of container is vital in the manufacturing industries, transportation, and material handling industries. They are well-built to provide safety and enable the carriage of large volumes of either liquids or other materials.

Custom Shapes and Sizes:

Apart from the basic dimensions, value-added packaging allows for the creation of containers tailored to particular uses. This could be, for example, shapes that allow for the optimal positioning of one container on top of another or functional add-ons such as handles or spouts. There is efficient storage and transportation of the products since sizes are tailored to match the actual needs hence minimizing wastage and improving the experience of every user.

Custom containers plastic

How Much Does Custom Plastic Containers Cost?

The cost of custom plastic containers depends on the type of material used, the size, and the quantity that will be produced in this case the cost will greatly differ. Here’s a more detailed breakdown:

Material Type

The cost is most affected by the type of polymer used. For instance, PET (Polyethylene Terephthalate) containers cost from $0.70 up to $3.00 per piece. It is popular for its high barrier properties and transparency, thus commonly used in food and beverage packaging. HDPE (High-Density Polyethylene) containers on the other hand, which range from $0.50 to $2.00 are usually used for household products because of their impact strength.

Container Size and Design

Pricing also depends on the size of the product. In the case of small containers (100-500 mL), the cost ranges from $0.50 to $3.00 per unit. These are best used where you are only going to use the container once, such as for holding sauce or cosmetics. Small containers (from 500 mL up to two liters) can cost from $2,00 to $5,00 ideal for shampoo or cleaning solutions. The cost rises with size, so large containers, 2L-10L, are $5.00-$15.00 because of the materials and manufacturing.

Productievolume

The results indicate that production volume is a determinant of the unit cost. Bulk purchases, in particular, can be made at a much cheaper price per unit. For example, if an organization placed an order for 10,000 units, the price per small container could be $1.00 while if an order is small, the price might be $2.50-$3.00 each. This is because, through economy of scale, the manufacturers can justify the setup and tooling costs against a larger number of units to be produced.

Customization Features

Custom features also directly increase costs; this includes unique colors and logos that may be printed on the equipment. For example, containers with special printing could cost an extra $1.00 to $3.00 per unit. Add-ons such as tamper-evident seals or particular caps also come at $0.10-$0.50 depending on their design and operation.

Tooling and Setup Fees

This is particularly so because initial tooling and mold costs may be high. The price for custom molds ranges from $5000 to $50000 depending on the design of the mold. Such costs are usually spread throughout the production cycle, and hence form part and parcel of the cost per unit, but are less sensitive to the size of the order.

Shipping and Handling

Finally, the cost of shipping has to be considered. While it may be cheaper to have the whole order shipped at once, per-item shipping can be cheaper with many items. Shipping was found to range from $0.20 to $1.00 per unit depending on the distance and the carrier chosen.

From these estimates, one can get a feel of the costs likely to be incurred in the production of custom plastic containers but as with most things, it is always a good idea to contact plastic container manufacturers for the most precise estimates, if you want to know more about cost about plastic products, you can go to kosten spuitgieten post to know more detail, or send us your custom plastic containers that we will quote you a price.

Technical Aspects for Custom Plastic Containers

Select materials that exhibit particular mechanical characteristics like tensile strength, flexural modulus, and impact strength. Use PET, which is known for its high clarity and moisture barrier, and HDPE which has a high toughness and chemical resistance. The performance of the material under operating conditions must be defined by stress-strain analysis and thermal analysis (DSC).

Tolerances of Dimensions and Geometry Optimization

Set tight tolerance levels on the dimensions using CAD tools to achieve good manufacturing. Utilize such geometrical optimization procedures that would allow the production of the minimum weight feasible whilst still sustaining the strength of structures. It can help to analyze the wall thickness variation and draft angles of the product to help facilitate better mal ontwerp and therefore, lower production costs.

Finite Element Analysis (FEA)

Appeal to FEA to model planar mechanical response to different loads. This analysis is useful in determining failure modes and can be used to make changes in the design by increasing thickness or putting ribs and gussets where stresses are high. Apply results for the container’s design to maximize its shape for better load distribution and to reduce the container’s chances of deformation during handling and transportation.

Barrier Property Engineering

Create layers of shielding that help to protect against oxygen, moisture, and ultraviolet light. Include EVOH or sorbents within the barrier layers as the means to extend the shelf life for the product in question. Conduct the permeation test to evaluate the efficiency of the barrier layers and conformity with the products’ storage standards.

Thermal and Processing Characteristics

Do thermal analysis to determine if the material will be stable under processing conditions as identified by Tm and Tg. Studying the thermal conductivity of the selected materials and how it will affect the performance of the stored and transported produce concerning temperature changes.

Regulatory Compliance and Safety Standards

Regulatory compliance and safety standards are major challenges that business organizations encounter when handling their correspondents’ mail. Make sure that compliance with the design also includes country/region-specific codes applicable to the food processing industry, FDA compliance for food-related items, or ISO for the pharmaceutical industry. Perform migration test to determine the possibility of substances leaching out of the container. Keep very detailed records for the purpose of compliance along with quality reassurance.

Tools Designed Methodologies

Choose the right technological process of manufacturing (injection molding, blow molding, thermoforming, etc.) considering the level of detail and quantity of products. The gate area as well as the cooling channel design should be analyzed to minimize cycle time and reduce defects. Ensure that the design concept works in practice by partnering with the manufacturers who can provide critique and input on the project’s actual practicality of the design.

Plastic verpakkingen op maat

Techniques For Manufacturing Custom Plastic Containers

Custom plastic Container manufacturers employ certain techniques for fabricating plastic containers. Some common techniques include;

1. Injection Molding

Injection molding is an accurate process of manufacturing in which pellets of thermoplastic are made to melt and are then injected at high pressure into the mold cavity. In the mold design, it must be taken into consideration that the polymer used shrinks at certain rates. The cooling phase is essential since it freezes the plastic and demands the best cooling channel design to minimize the cycle time and promote equal cooling. This method is suitable for mass production of intricate shapes and produces near-net components with good dimensional tolerances and surface finishes.

2. Blow Molding

Blow molding is a process of making hollow plastic items through the process of blowing up a parison. It involves heating the thermoplastic material and then shaping it into a parison and finally, it is clamped on a mold. This is done through high-pressure air being introduced into the parison thus causing it to expand and push against the walls of the mold. Parameters of parison temperature, mold temperature, and air pressure have to be maintained at optimal levels to obtain identical wall thickness and to minimize such defects as sagging or improper blowout.

3. Thermoforming

Thermoforming is the action of heating a thermoplastic sheet to the point where it gains its flexibility and then draping it over a mold and applying vacuum or pressure to give it the required form. These concerns are heating temperature, heating time, and the mold design where features such as vents that allow air escape during formation can be fabricated. The cooling phase is important for holding the shape as well as the dimensional stability of the material. This method is most appropriate for fewer runs and simple geometries as compared with injection molding.

4. Rotational Molding

Rotational molding uses a powdered plastic that is put into a closed mold, the mold is heated and rotated along two perpendicular axes. When the mold is in rotation, the powder melts and forms a layer on the surface of the mold, thus making it a hollow part. The symmetry of the wall thickness is the foremost factor, which is dependent on the rotation rate and heating duration. This method is also suitable for large parts that are used for such applications as storage tanks where accuracy, material consumption, and the possibility of including inserts in the mold are critical.

5. Extrusion

Extrusion is the process whereby plastic pellets are heated and then put through a die to produce a continuous shape of sheeting, tubes, or profiles. The flow properties as well as the final dimensions of the article depend on the barrel temperature, screw speed, and die design. It also plays a vital role in ensuring shape integrity, normally by way of water baths and or air cooling. Extrusion is very cost-effective for high-volume production of regular cross sections and is often followed by secondary operations to provide finishing.

6. Amalgamated Manufacturing/ Additive Manufacturing/ 3D Printing

Additive manufacturing is a process of building up a part layer by layer from a digital model of the component to be produced using 3D Printing. It uses thermoplastics and photopolymers among others, and each layer is accurately either deposited or cured. These are the layer height, print speed, and infill density, these parameters determine the mechanical strength and surface quality of a final part. This kind of production is very useful in rapid prototyping and custom production where someone wants his product to be unique but lacks the high-speed production needed for bulk production.

7. Pressure Forming

Pressure forming is an improvement of the thermoforming process in that heat and positive pressure are used to form the plastic sheet. This technique affords higher detail and better draws compared to the common thermoforming in view of this it is appropriate for high fidelity. This means that the process parameters such as pressure, heating time, and cooling methods are critical in the process. There may also be additional features for air extraction and for controlling the flow of the material during forming.

Custom Plastic Containers with lids

Benefits and Limitations of Custom Plastic Containers:

Here’s a table outlining the benefits and limitations of custom plastic containers:

Aspect Voordelen Beperkingen
Aanpassing Tailored designs to meet specific needs. Higher initial costs for custom molds and tooling.
Materiaalvariatie Wide range of materials available (e.g., PET, HDPE). Limited thermal resistance for some materials.
Lichtgewicht Reduces shipping costs and enhances portability. May lack durability compared to heavier materials.
Kosteneffectiviteit Economies of scale for large production runs. Smaller runs can lead to higher per-unit costs.
Barrier Properties Excellent moisture and oxygen barrier options. Not suitable for all chemical applications.
Ontwerpflexibiliteit Complex shapes and features can be easily integrated. Tooling for complex designs can be expensive.
Sustainability Options for recyclable and biodegradable materials. The environmental impact of plastic waste remains.
Productiesnelheid Fast production times for high-volume orders. Slower for low-volume or one-off custom projects.
Aesthetic Appeal High-quality surface finishes and branding options. Some finishes may require additional processing.

Types of Materials for Custom Plastic Containers

The are many types of plastic materials are used to make palstic containers, below are common materials are mostly used for csutom plastic contatiners manufacturing.

  1. Polyethyleentereftalaat (PET)
    PET is a lightweight, clear plastic that is highly resistant to moisture and offers excellent durability. It’s commonly used for water bottles and food packaging because it preserves freshness and prevents contamination. Its recyclability makes it a popular eco-friendly choice. Go to PET injection mlding pagina voor meer informatie.
  2. Hoge dichtheid polyethyleen (HDPE)
    HDPE is a strong, dense plastic known for its toughness and resistance to chemicals and impacts. It’s used for containers like milk jugs and detergent bottles. HDPE is less prone to cracking and is widely recycled, contributing to its popularity for packaging. If you want to know more about HDPE material you can go to HDPE-spuitgieten pagina.
  3. Polypropyleen (PP)
    PP is a versatile plastic with a high melting point, making it ideal for items like food containers that need to withstand microwave heating. It is also durable, lightweight, and resists chemicals, making it suitable for various household and industrial products. Go to polypropyleen spuitgieten pagina voor meer informatie.
  4. Polyvinylchloride (PVC)
    PVC is a durable plastic that can be either flexible or rigid. It’s often used in food wrap, medical containers, and plumbing pipes. While highly versatile and cost-effective, PVC requires special recycling processes due to its chemical composition. Go to PVC injection pipe fitting mold pagina voor meer informatie.
  5. Low-Density Polyethylene (LDPE)
    LDPE is softer and more flexible than HDPE, making it ideal for squeeze bottles, grocery bags, and cling wrap. It offers good resistance to moisture but isn’t as strong as HDPE. Its flexibility and transparency make it useful for various packaging applications. Go to PE-spuitgieten om meer te weten.
  6. Acrylonitril-butadieen-styreen (ABS)
    ABS is a tough, impact-resistant plastic often used in products like electronics housings and automotive parts. It’s known for its rigidity and ability to withstand high-stress environments. Its glossy finish and strength make it ideal for durable consumer goods. Go to ABS-spuitgieten pagina voor meer informatie.
  7. Polystyreen (PS)
    Polystyrene can be either rigid or foamed. It’s commonly used in disposable cups, food containers, and insulation materials. While affordable and versatile, it’s less eco-friendly because it’s harder to recycle and often used in single-use products. Go to PS-spuitgieten pgae to know more.
  8. Ethylene Vinyl Alcohol (EVOH)
    EVOH is a plastic with excellent barrier properties, particularly against gases like oxygen, making it perfect for food packaging that needs to preserve freshness. While not used on its own for structural purposes, it’s often combined with other plastics to improve their performance.
  9. Polycarbonaat (PC)
    Polycarbonate is known for its transparency and toughness. It’s often used in products like reusable water bottles, eyewear lenses, and protective panels. PC is valued for its strength, but care must be taken as it may contain BPA, a chemical of concern in some applications. Go to polycarbonaat spuitgieten pagina voor meer informatie.
  10. Bioplastics (PLA, PHA)
    Bioplastics such as Polylactic Acid (PLA) and Polyhydroxyalkanoates (PHA) are derived from renewable resources like corn starch or sugarcane. PLA is commonly used for compostable food packaging, while PHA is more durable and used in medical and agricultural applications. Both are praised for their reduced environmental impact compared to traditional plastics.

custom plastic containers

Final Summary

In conclusion, the application of creating custom plastic containers demands the selection of the right material and manufacturing processes appropriate to the use of the containers. These include mechanical properties, chemical compatibility, and rate of fabrication. Injection molding, blow molding, and 3D printing are some of the more sophisticated manufacturing techniques that each has its strengths which need to be balanced against cost, volume, and complexity of design. By applying these findings, the manufacturers can enhance the utilitarian and ecological features of plastic containers along with meeting sectoral regulations.

Veelgestelde vragen

Q1. What factors influence material selection for plastic containers?

Factors that determine material choice include; chemical resistance, mechanical properties, thermal properties, and statutory requirements. Such characteristics guarantee the containers meet the precise requirements of the applications they are used for, not to mention safety.

Q2. How does the manufacturing method affect costs?

The decision of how to make a product affects costs by factors such as tooling costs, the number of parts produced, and the time taken to produce each part. For example, technologies such as spuitgieten where a large number of items are produced at once, minimize costs where many items are being produced at once.

Q3. What are the benefits of using bioplastics?

One, bioplastics are manufactured from renewable resources, and the majority of them are biodegradable. It can enhance a brand’s sustainability position and parents looking for a suitable brand of products that use socially conscious packaging materials.

Q4. How do plastic container manufacturers ensure safety compliance?

The plastic container manufacturers can guarantee safety by carrying out tests of migration and leaching while also obeying the safety measures of the various industries. Recording and tracking of such materials utilized in the production process is critical to validation and conformity to safety requirements.

Militaire behuizingen op maat

Op maat gemaakte militaire behuizingen are blonging to military supplies, which have high quality requirement on both material and manufacutring. If you are involved in the electronics or computer industry then you are well aware of enclosures like PCB enclosures or electronic boxes etc. They improve the efficiency of the devices and also organize and shield inner parts from various outside factors.

While designing an electronic custom rugged military enclosure, the following aspects should be taken into consideration. One of the most important is to guarantee that the final product stays affordable at the end of the day. Subconscious choices can reduce costs including choices of material, surface finishes, and other options in the manufacturing process.

In this article, I will describe the steps necessary for designing an application-specific enclosure for an electronic product and will emphasize the goals of efficiency and cost optimization.

aluminum enclosure

Custom Rugged Military Enclosures Design Process

There are several crucial phases through which the custom enclosure design is taken to achieve certain functions, appearance, and fabrication. Here’s an overview of the key phases in designing a custom fugged military enclosures:

1. Define Requirements

Start with an understanding of the need to fully specify the project scope. These are; the application for which the product is intended, the conditions it will work under, and any standards that the product has to meet. Other considerations also include size, weight, and the appearance of the equipment should also be considered.

2. Material Selection

Selecting the appropriate materials is a core factor as far as efficiency and expenses are concerned. These are aluminum, steel, and various types of plastics some of the advantages being strength, weight, and heat dissipation. To choose the materials the environment of the enclosure should be considered so that it can offer the required protection against moisture, dust, and thermal changes.

3. Conceptual Design

Once requirements and materials are established then pass on to the generation of some primitive ideas. This phase may include drawing and prototyping, to make a layman’s conceptualization of the enclosure and how it will be used. It is possible to work with engineering teams to do further tuning on these concepts and to discover other potential design problems.

4. Prototyping

The idea of creating a prototype is useful to get feedback on the design before going into large-scale production. Using the example of 3D printing, one can acknowledge that it is easy to make changes during the process of product development since the process of prototyping is very fast. Fit, form, and function are all examined with prototypes so that all parts are known to fit as planned.

5. Testing and Validation

It is possible to write with ease the algorithm that defines the necessary questions, but to come out with a valid prototype on the first try may not be possible as what is required next is critical testing of the prototype to determine how well it is going to perform. These are mechanical integrity, thermal, and environmental protection checks. If any problems exist during testing then the solution should be a design modification.

6. Final Design Adjustments

Using the results of the testing again make the necessary changes to arrive at the final look and feel of the UI/UX. This may entail changing dimensions, modifying mounting features, or changing the material to improve the performance and affect the cost.

7. Production Planning

After defining the design, it is necessary to come up with a plan for production, manufacturing processes, tools necessary, and expenses. Cooperate with manufacturers to guarantee that the production processes correspond to design requirements as well as manufacturing quality control procedures.

8. Manufacturing

After the production plan, the manufacturing phase starts with the production of the new product. This entails the crafting of the actual enclosures from the chosen material and manufacturing processes. Play is also plausible by monitoring the quality of products on the production line to ensure that the designs are not distorted.

9. Assembly and Quality Assurance

After manufacturing, the enclosures experience the assembling process and are then subjected to quality control tests. This will help to ensure that all components are well installed in the final product and that such product meets the needed standard as it is taken to the markets to be sold to the customers.

10. Feedback and Iteration

Last of all effectiveness check post-deployment with the users and the stakeholders. This information is useful in future designs and is an important source of feedback that can be used to enhance future designs.

custom rugged military enclosure

Different Methods Used to Manufacture Custom Machined Military Enclosures

Machining is a very flexible manufacturing process frequently used in assembling customized enclosures, especially where accuracy and intricate features are important. It is a material removal process in which the workpiece is produced from a solid block or sheet of the material by cutting away unwanted material. As mentioned above, here is a brief of the basic machining strategies used in the construction of custom enclosures and their relative merits.

CNC Milling

CNC (Computer Numerical Control) milling is the process that uses state-of-the-art computer-operated machines to progressively cut material from a workpiece. This technique works well where the required cross-sectional shape is diverse, for example, cut-out slots, undercuts, or precise locating dimples. CNC milling allows for a wide variety of materials, which include different types of metals and plastics, and therefore can be used in a variety of applications, from lightweight electronics casings to heavy-duty industrial coverings. Its advantages for high-speed machining and multi-axis operation also improve design freedom and accuracy.

CNC Turning

CNC turning is used in the production of cylindrical parts where the workpiece is revolved with a cutting instrument. The process is optimal for making the CNC aluminum enclosure parts such as cylindrical casings, end covers, and threaded parts. CNC turning is precise and consistent allowing the production of close tolerances necessary for parts that need to fit well and perform their intended functions. This method also allows for fast cycle times, thus it is ideal for short and long runs.

Waterjet Cutting

Waterjet cutting takes advantage of a high-pressure water jet, which may be accompanied by abrasive granules for cutting operation for the different types of material suitable for waterjet cutting such as metals, plastics, and glass. This technique has a special feature of providing sharp edges and at the same time preventing the formation of thermal distortion, which is very useful for creating complex patterns and thin-walled products. Waterjet cutting also proves advantageous when manufacturing enclosures that require specific shapes or panels that require large contours, while still allowing manufacturers to manufacture highly detailed enclosures without adverse effects on the material.

Laser Cutting

Laser cutting entails the use of laser light to cut through a material to the desired thinness with a lot of precision. The technique is also preferred for thin material because the intricacy of the design and achieved surface smoothness is highly probable when using this technique. Some of the uses include making panels, lids, and flat parts of enclosures. Due to the high speed and accuracy of laser cutting, it can be effectively used both in the prototyping stage and in the mass production of products, which will benefit manufacturers in terms of time and quality.

CNC Routing

Routing operation uses a rotating cutting tool to cut material from the surface of a workpiece. It is frequently applied to produce flat parts like panels and covers and can accommodate any type of material, wood, plastic, or metal. It is advisable in the routing since it can be done in detail and applied to branding, labeling, and other features such as cutouts on the enclosures.

Electrical Discharge Machining (EDM)

Electrical Discharge Machining (EDM) is another nontraditional, computer-controlled machining technology that utilizes sparks to remove material from work pieces.

EDM is a non-conventional machining process that utilizes an electric spark to remove material from the electrically conductive material. This method offers the best way of developing narrow sections, undercuts, slots, and holes which would otherwise be challenging to make using regular cutting instruments. EDM is most suitable in making molds and dies on the enclosure parts, where accuracy and good surface finish are desirable.

rugged military enclosure

Considerations for Precision and Other Factors in Machining Custom Enclosures

When using machining to manufacture custom enclosures, there are many precision factors and concerns involved to achieve the right outcome and functionality. Here are the key aspects to consider:

1. Tolerances

Tolerances established the level of variation in the dimensions of the enclosure. Machining with high levels of accuracy can be done to precise limits of tolerance, which is very important where the components require a high level of accuracy such as a tolerance of ± 0.001 inches or better. It is crucial to comprehend the necessary tolerances so that assembled components won’t have problems in their operation.

2. Material Choice

Machinability depends on the type of material to be processed and the precision to be achieved in the final product. For example, working with metal, such as aluminum or stainless, allows achieving very precise interferences, while when working with plastic materials, some kind of precautions must be taken to avoid deformation of the material. To achieve the best result it is crucial to select a material that will satisfy the need of performance as well as the potential of the machining method.

3. Machining Method

Precision is affected by the kind of machining method chosen. CNC milling and turning provide high accuracy of the workpiece, and water jet cutting and laser cutting provide very good edge quality although the accuracy may vary depending on the thickness and type of material being cut. This decision depends on the complexity of the design and the degree of accuracy needed to determine the best approach.

4. Tooling

The type and condition of tooling greatly affect the level of accuracy of machining. Tools that are of high quality and sharp with specific cutting edges can deliver the best standards of cutting the material with less tolerance. Great care must be taken to see that tools used in forging are well selected and maintained appropriately to retain suitable accuracy.

5. Fixturing

Correct clamping means that the workpiece is well secured in position during the machining process, and will not shift around leading to unsatisfied tolerances. Good location of fixtures ensures that there is little or no deviation from the machining process and also allows for several operations to be conducted ensuring high accuracy.

6. Machine Calibration

Machining equipment needs to be calibrated always to ensure that the desired accuracy is achieved. It is suggested that machines should be checked and adjusted to guarantee that the deviations from their ideal values are within a particular range. This is especially the case with CNC machines where even slight variations can be a large source of error in the production of the final product.

7. Surface Finish

The required surface finish thus influences the enclosure’s performance, appearance, and construction. Various types of machining operations produce surfaces of different characteristics, therefore, the required surface finish should be agreed upon at the design stage. Further finishing may be necessary for obtaining the final finish; for example, sanding, painting, electricplating, polishing, or anodizing.

8. Production Volume

A consideration of precision may be affected by the expected production volume. When it comes to mass production, the quality and accuracy of the product become very important for every part that is being produced. On the other hand, low run volumes or prototype runs may afford greater tolerance and surface finish perimeters.

9. Thermal Management

Machining operations may produce heat that in turn alters the properties of the material and its accuracy. When using flood cooling or misting, it is possible to prevent dimensional changes during the process of machining.

Op maat gemaakte militaire behuizingen

Choosing the Right Finish for Custom Enclosure Designs

Choosing the right finish for custom enclosures is critical since it defines the unit’s utility and appearance. This element determines the resistance, the look, and the efficiency of the product. Below are some of the above-mentioned finishing techniques and the features associated with each of them.

1. Anodizing

The anodizing process forms a chromate coating on the surface of the aluminum enclosure to act as a shield to the metal part. The next layer increases the level of corrosion protection. Its thickness usually varies between 5 and 25 microns. This also enables various colors which have an aesthetic touch to the whole structure.

2. Powder Coating

Powder coating is the process of applying a dry powder that needs heat to be applied and to dry. This leads to an external layer that is rather delicate and quite hard to penetrate. Layer thickness normally ranges from 40 to 100 microns. It is available in diverse colors and finishes and therefore has a good appearance.

3. Electroplating

Electroplating is a process of plating one metal onto a substrate by depositing a thin layer of that metal on the substrate. Some of the everyday metals are nickel and chrome. The layer thickness range is from 1 to 25 microns. This method increases the corrosion protection and gives a shiny look to the surface of the article.

4. Painting

Painting is a process of applying liquid paint onto the surface of the enclosure. This method provides a lot of opportunities to choose a color and design. Usually, the layer thickness varies from 25 to 75 microns. While it gives the building an environmental appearance, the work may need frequent touch-ups after some time.

5. Brushed Finish

A brushed finish is a surface finish obtained by using abrasives to provide a textured surface. This technique does not add extra bulk to the process. It mainly changes the surface roughness. It gives a different appearance and a little bit of protection from rust.

6. Polishing

Polishing has the effect of making the surface reflective. This process reduces thickness but does not add material to the workpiece. It also improves the aesthetic value of the enclosure. The smoothness of surfaces also enhances corrosion.

Military Specifications for Custom Enclosures

Military applications require high accuracy enclosures which should be designed and produced under the Mil-Spec requirements. These custom rugged military enclosures must have high mechanical strength, and high corrosion resistance, and have to be produced within very close tolerances. This is a good reason why thorough quality control must be applied in the entire manufacturing process to ensure that the product performs as expected. It is common for documentation to be necessary to prove conformity with material and workmanship requirements.

There are other op maat gemaakte elektronische behuizingen van kunststof which made by plastic injection molding or machining process, some of those plastic enclousures  are used in the militery industry as well.

Key Compliance Requirements

  • Material Certification: There is also a need to state the type, grade, and specification of the material to be used. Certification guarantees that all materials have the necessary performance characteristics.
  • Certified Material Test Report (CMTR): This report, signed and dated, describes the material type, grade, and specifications, as well as mechanical or chemical characteristics. It is used as a document that comprises quality verifications of the material.
  • Process Certification: Welding, painting, and plating processes for example are required to be certified by the National Aerospace and Defense Contractors Accreditation Program (NADCAP). The purpose of this certification is to guarantee that production processes are commensurate with the requirements of the industry in terms of quality.
  • Manufacturing Origin: In this case, enclosures must be sourced from the USA, or from a country that meets strict guidelines. This is especially important regarding the different regulations governing contracting for military services.
  • DFARS and FAR Compliance: You need to follow the DFARS and FAR strictly. These regulations set out policies on the procurement of defense-related products and guarantee their implementation in the chain.
  • ITAR Compliance: The ITAR regulates the transfer of defense articles and technology both into and out of the United States. It is mandatory for all uses of military products.
  • Testing and Inspection: Sometimes it may be necessary to perform third-party testing to ensure the product does not leak or fail at some point. This commonly includes a First Article Inspection (FAI) that is meant to validate the dimensions of each part or assembly to a tolerance and performance level.

Understanding Your Project Challenges

When entering the projects of custom enclosure, there should be an understanding of certain technical issues that may affect the design and construction. Here’s a focused overview:

1. Design for Manufacturing and Assembly (DFMA)

It is critical to adopt DFM principles in order to realize that new product designs can be effectively produced. This means evaluating geometric characteristics in addition to material type and joining techniques in order to avoid manufacturing difficulties. Working with engineers can help to design parts more effectively, minimize tooling, and reduce the time to cycle.

2. Cost Reduction Strategies

The need to reduce cost during the production of existing products calls for technical analysis of the present manufacturing techniques. This can be in the form of considering material choices for the product, improving the process methodology of machining, or even redesigning parts that can be assembled easily. Value engineering can be used to reduce costs while maintaining the quality of the item.

3. Quality Control Measures

In projects that need high tolerance levels, quality checks and balances must be initiated. By so doing, there is compliance with the set tolerances through the usage of sophisticated equipment like the CMM and the optical comparators. Using statistical quality control provides methods that would assist in controlling the quality of production.

4. Timeliness of Delivery

To solve delivery issues, one has to evaluate production capacity and the time that is taken to deliver products and services. Effectively, organizational change aimed at the application of lean manufacturing improves cycle times and capacity utilization. The use of automated project management systems to monitor the actual state of production schedules guarantees the timely delivery of components.

5. Production Capacity Control

In case of capacity problems, it is necessary to provide a technical evaluation of the current production capacities. Some of the strategies are changing the forecasted production time, shifting resources, or employing flexible manufacturing resources. This can be done without necessarily increasing more units of output and at the same time improving the quality of the product and operational efficiency.

Conclusie

The technical issues in custom enclosure projects are important to be solved to achieve positive results. Design for manufacturability, cost reduction measures, adherence to quality, delivery schedule, and improving production throughput are some of the ways that manufacturers can improve efficiency and gain reliability. Such an action in these areas will not only ensure that it meets the specifications but also enhance the project’s performance and customer satisfaction.

Voedselveilig plastic

7 Types of Food-Grade and Food-Safe Plastics

As far as food safety is concerned, information concerning packaging and storage materials is important. Not all plastics are safe for food contact. So, it is crucial to learn about food-safe plastics. Some insights on making the right choice can go a long way in improving both health and food quality. In this article, you will find out what food-grade and food-safe plastics mean, their main characteristics, the legislation governing them, and their main uses.

What is Food Grade?

Food contact material is safe to use in direct contact with food. These materials have no bitter taste that may affect the food and are included in packaging, cutleries, etc. An economic view of food-grade material is that such items cannot be used in food production if they don’t meet some requirements from authorities, i.e. FDA approval plastics.

What is Food-Grade Plastics?

Food-grade plastics are special plastic types certified by food-contact administrative bodies to come into contact with food. They are subjected to rigors to check their ability to contaminate foods with chemicals or toxins.

Food-Grade plastics

What is Food-Safe Plastics?

Food-safe plastics can be defined as plastics with features and characteristics that make handling, storage, or transportation of food possible. It should be noted these plastics do not disintegrate easily or leach out toxic chemicals when exposed to food, heat, or moisture.

Food-Safe vs. Food-Grade

For “food-safe,” which means that a material is safe for food contact under conditions that are considered standard, “food-grade” means that the material is compliant with the FDA or other regulating bodies. All food-contact plastics are food-safe but not all food-safe materials qualify classified as food-grade.

All You Need to Understand About BPA

Bisphenol A or BPA is a compound used in plastics that can migrate to foods or drinks. Research indicates that BPA may pose some dangers if ingested, therefore; various authorities have sought to limit the use of this chemical in food contact applications. We should pay attention to plastic food wraps labeled as ‘food-grade’ containing BPA, which should be eliminated.

Methods of manufacturing food grade plastic products

The food-grade plastic products require the correct type of direct material, preventive measures against contamination, and a proper processing method. Here’s a breakdown of how to produce food-grade plastic products:

FDA food grade plastic

1. Selection of Raw Materials

The process starts with procuring the best raw materials chosen to meet the actual and required food safety standards. It must not contain chemicals that are toxic and can migrate into foods, examples of this chemical include Bisphenol A (BPA) and phthalates. Plastics allowed include those that meet this status at the international, federal, or state level, i.e. United States Food and Drug Administration (US-FDA) approved plastics are used. Some familiar Food Grade Plastics may include PET, HDPE, PP, and LDPE.

2. Compliance with regulatory standards.

Manufacturers need to ensure that the materials of plastic and additives used are safe for use with foods as identified by the FDA (United States) and the EFSA (Europe). They test to ascertain that no dangerous migratory substances are present on the materials for transfer into food. Food-contact plastics standards, i.e., insist on the purity and composition of the material before the FDA allows them to be used for food storage or packing.

3. Good Manufacturing Practises (GMP)

Production of food-grade plastics involves the adherence to good manufacturing practices (GMP). GMP includes cleanliness, keeping all parts and processes uncontaminated, and cleaning the machines and equipment. This implies that the firm has control over the introduction of raw materials through to the packaging of the final product.

Food-Grade plastic material

Key GMP principles include:

  • Proper Facility Maintenance: Production facilities should be clean and they should not have any contaminants at all.
  • Machine Sterilization: Equipment used for production purposes is always cleaned to eliminate any possible cross-linking with diseases.
  • Employee Hygiene and Training: Employees in the manufacturing of food-grade plastics are trained to handle the product appropriately together with cleanliness.

4. Blow Molding Injection Molding or Extrusion

Outputs start with the selection and quality control of raw materials. Here the plastic is formed by processes such as injection molding or extrusion.

  • Spuitgieten: These plastic pellets are melted by heating, and then forced into molds which form containers, bottles, or other shapes.
  • Extrusion: Plastic use involves melting and extruding through a die to form continuous structures common as sheets and films.

Both fabrication techniques ensure accuracy in dimensionality plastic thickness, and strength, which is important for food compliance.

Food safety plastics

5. Testing for Safety and Compliance

Plastic products go through various tests to meet the necessary safety standards. These tests determine the efficiency of chemical leaching, thermal stability, and the service life of the conditioned vegetable oil. Food-contact plastics do not chemically interact with the food-contacting surfaces, and should not be damaged by heat. Besides this, they should not degrade and leach out any dangerous chemicals.

Some of the tests include:

  • Migration Testing: Make sure that the specific chemical migrates into food to an extent not greater than the allowable level even under the stated conditions like heating or freezing.
  • Strength and Durability Testing: Checks for plastic toughness to determine if it will not break or dematerialize.

6. Labeling and Certification

When the food-grade plastic meets all safety and compliance requirements, it gets its official labels. Customers and regulatory bodies such as FDA offer accreditation, to products that work to specified safety measures. Manufacturers like to add claims such as ‘BPA free,’ ‘FDA approved,’ or the recycling symbol that denotes the type of plastic, i.e. 1 for PET, and 2 for HDPE. These labels assist the customer in differentiating between the safety and the appropriateness of the product for food use.

7. Sustainability and Recyclability

Recent years have improved attempts at keeping up with sustainability in food-grade plastics production. Increased consumer awareness is creating pressure on most manufacturers to adopt either post-use-recycled plastic material, i.e. food grade, or look for biodegradable plastics. That is why, ensuring that food-grade plastics are recyclable and are friendly to the environment is an essential factor today.

FDA grade plastic

7 Types of Food-Grade Plastics

Here are some common types of plastics we can use as Food-Grade and Food-Safe;

1. Polyethylene Terephthalate  (PET or PETE)

PET is generally used to make water and soda bottles and food containers, i.e. peanut butter jars. It is light, tough, and very effective in barring moisture hence its use in packaging. PET is also (ed code: 1) highly recyclable but is best used only once as it may degrade if used continually.

2. High-Density Polyethylene (HDPE)

HDPE is used in milk jugs, juice containers, and grocery carry bags. It is non-breakable, hard-wearing, chemical and shock resistant, and it is food safe as it does not contaminate food products. HDPE is a flow category, it is also recyclable material and marked by recycling code “2”.

food grade container

3. Polyvinyl Chloride (PVC)

We can use PVC in containers but avoid it in high-heat applications because it releases toxic chemicals. It is more robust but used least in food preservation particularly where heating is needed and is stamped with code “3.” PVC are mostly used for pipe fitting mold. klik hier to know more about PVC pipe fitting injection molding.

4. Low-Density Poly Ethylene (LDPE)

Examples of products that use LDPE include; bread and frozen food bags and some flexible packaging. This material is light, versatile, and does not absorb moisture. Therefore it can be used to store foods. Besides this, LDPE is recyclable with the code “4”, but it gets recycled more rarely than other materials.

5. Polypropylene (PP)

PP is most commonly used in yogurt cups, disposable and reusable straws, caps of soda, and beer bottles. That is why, it is heat resistant and suitable for food packaging or products that can be heated in a microwave. PP is safe, durable, and recyclable with code ‘5’. Go to is polypropyleen spuitgieten page to know more about this PP material.

Food grade plastic part

6. Polystyrene (PS)

PS is applied as disposable forks, spoons, knives, cups, and plates. It may be lightweight and affordable, but it’s not the best material for long-term food storage because of fears of chemical leaching, especially when exposed to heat. It’s marked with code “6.” Go to PS-spuitgieten pagina voor meer informatie.

7. Polycarbonate (PC)

It is used in reusable water bottles and food storage containers. It may include BPA, a chemical capable of causing health effects. While these materials are strong and transparent, we should pay extra attention not to using products that include BPA. Furthermore, the PC is noted with recycling code 7. Go to polycarbonaat spuitgieten pagina voor meer informatie.

7 typs of food grade plastic

Key Properties Of 7 Types of Food-Grade Plastics

Here are some important types of plastic along with their properties and applications in different industries;

Plastic Type Recycling Code Common Uses Duurzaamheid Hittebestendigheid Chemische bestendigheid BPA-Free Recycleerbaarheid
Polyethylene Terephthalate (PET or PETE) 1 Beverage bottles, food jars Hoog Laag Gematigd Ja Hoog
Hoge dichtheid polyethyleen (HDPE) 2 Milk jugs, juice bottles, grocery bags Zeer hoog Gematigd Hoog Ja Hoog
Polyvinylchloride (PVC) 3 Cling wraps, food containers Gematigd Laag Gematigd Can contain BPA Laag
Low-Density Polyethylene (LDPE) 4 Bread bags, frozen food bags, containers Gematigd Laag Hoog Ja Laag
Polypropyleen (PP) 5 Yogurt containers, bottle caps, straws Hoog Hoog Zeer hoog Ja Gematigd
Polystyreen (PS) 6 Disposable cups, cutlery, plates Gematigd Laag Laag Can contain BPA Laag
Polycarbonaat (PC) 7 Reusable bottles, food storage Zeer hoog Hoog Hoog Can contain BPA Laag

 

Five Prominent Features of Food-Safe Plastics;

The following are key features of Food-safe and Food-grade plastics;

  1. BPA-free and toxin-free
  2. Heat-resistant and durable
  3. Inert to food substances
  4. Odorless and tasteless
  5. Authorized by regulatory authorities (FDA food plastics, EU, etc.)

 

Are there any plastic food bottles Safe?

Yes, food-grade plastic bottles and containers are safe to use for human consumption as long as they have been properly washed up, non-BPA type. FDA must approve such product and it should not be damaged over time.

FDA food grade material

 

Plastic Numbers  Safe for Food Storage

Recyclable plastic types one, two, four, and five, i.e. PET, HDPE, LDPE, and PP are safe for storing foods. Eschew plastics that have a code 3 (PVC), 6 (PS), and 7 (Other) since these plastics contain BPA and other unfriendly chemicals.

FDA food grade plastic spoon

Safe Plastics Number Chart for Food-Grade Plastic

The following table will help us understand what Fodd-Grade plastics are Food-Safe as well;

Plastic Type Safe for Food Contact? Common Use Cases
1 (PET or PETE) Ja Water bottles, containers
2 (HDPE) Ja Milk jugs, juice bottles
3 (PVC) No Cling wraps, containers
4 (LDPE) Ja Bread bags, frozen food bags
5 (PP) Ja Yogurt containers, bottle caps
6 (PS) No Disposable plates, cups
7 (Other) Depends (avoid BPA) Miscellaneous items

Applications for Food Grade and Food Safe Plastics

Here are some common applications of Foof-Grade and Food-Safe plastics;

  • Laboratory consumables such as food trays and food packing materials
  • Beverage bottles
  • Utensils and cutlery
  • Paper bags and foils
  • Industrial Applications Food Processing Equipment

Benefits of Food-Grade and Food-Safe Plastics

Let’s discuss some pros of Food-Grade and Food Safe plastics;

  1. Inexpensive and easy to manage
  2. Durable and shatter-resistant
  3. Resistant to contamination
  4. Versatile and easy to mold
  5. Reusable (if the type of disposable product is taken into consideration)

Food grade containers

Disadvantages of Food-Grade and Food-Safe Plastics

Here are some cons/limitations of Food-Grade and Food-Safe Plastics

  1. Potential for environmental harm (plastic waste)
  2. Some plastics can hardly be disposed of when heated – they emit toxic substances.
  3. Though most are designed to be shop-safe, not all are microwave or dishwasher-safe.
  4. Some have limited alternatives for recycling.
  5. Long-term durability may vary.

Conclusie

In conclusion, Food-grade and food-safe plastics are important components in the food industry’s packaging and preservation solutions. General knowledge of the type of plastic used and the recognition of environmentally friendly products are critical to health and safety. The food and beverages stored will be protected from being contaminated by using BPA-free, FDA food plastics whenever you select them.

Veelgestelde vragen

What does “food grade” mean?

Food-grade means that plastic material can be relayed to the food and it is compliant with legal requirements.

Are BPA-free plastics always safe for food storage?

Yes, BPA-free plastics are a little safer but then make sure that these plastics that you use are food-grade ones.

Can I use any plastic container for food storage?

No, only use containers marked as food-grade or food-safe on their surfaces.

Can the same plastic containers be used again?

Yes, if they are freshly packed, hygienically stored, and in a food contact permissible material. If it’s worn or cracked then recommended not to use it.

What kind of plastic is better for storing food for a longer period?

HDPE and PP plastics are safe for long-term use due to the material’s rigidity and lack of potential chemical reactions.

Why should I avoid plastics labeled with 3, 6, and 7?

These plastics have been known to release pathogens like BPA through heat and moisture impacts.

Spuitgietmal

We often need metal parts in various shapes. We use them in our cars, houses, machines, and other infrastructures. Have you wondered how it is possible to make such a detailed shape? Die Casting mold tech has revolutionized our lives. With this method, you can create complex shapes and patterns. Die-casting mold parts are widely prevalent in a wide range of applications.

In this article, we will learn some fundamentals about die-casting mold. In addition, it’s gonna be an excellent guide for those looking for the best die-casting services. You will learn how foundries make die-casting molds. So, sit tight and read this article thoroughly.

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Overview of Die Casting

Die Casting is a famous type of metal casting process. As the name implies, this method typically uses specific dies for the job. The shape of the final metal part depends on the shape of the dies. Although there are different types of die casting, the base technology is the same for all. The material used for making these molds is hardened tool steel.

Die casting has a long history. People invented this tech in 1838. In the early times, this application was only for printing purposes. Later, as technology developed, people usually learned how to use this method to create various complex metal parts. Die casting offers several benefits.

  • Die-casting mold typically offers high production efficiency. This part is comparatively faster than other permanent mold casting processes. As a result, you can create hundreds of metal parts in less time.
  • Die-casting mold parts usually come with a smooth surface finish. For HPDC metal parts, this is more obvious. As a result, you might not need additional machining services.
  • The die-casting method is versatile. It generally works with many metals, including aluminum, zinc, and magnesium.
  • Since this method is fast, it generally reduces production costs. Although creating the dies may be expensive, this method is cheaper in the long run.
  • Die-casting mold parts are widely prevalent in many industries. This method makes your car’s engine, gearbox, and structural parts. You may also find similar applications in other sectors as well.

Different Types of Die Casting

Die casting typically has six major types, each with its own perks. Each type is suitably suited to specific applications. Let’s look at their particular technology and product use.

Type #1 HPDC (High Pressure Die Casting)

As the name suggests, this die-casting method requires high pressure for the job. This hogedruk spuitgieten technically pushes the molten metal to every mold corner. As a result, you can get very precise metal parts.

In the car industry, engine blocks and gearbox castings are made of high-quality HPDC aluminum parts. Various equipment and infusion pumps are noteworthy in the medical industry. Besides, many aircraft components also need HPDC casting metal parts.

Type #2 LPDC (Low-Pressure Die Casting)

This die-casting method is just the opposite of HPDC. It involves low pressure, typically ranging from 2 to 15 psi. The process is almost similar, but it is generally slower than HPDC. Since it is slow, you can easily control the movement of the molten metal.

LPDC metal parts are widely prevalent for car wheels, cylinder heads, and suspension systems.

Type #3 Gravity Die Casting

This die-casting method uses gravitational force to fill the mold with molten metal. The process typically pours the molten metal into the mold from above, and the liquid flows downwards. It is simple and cheap because it doesn’t need additional forces.

De gravity die-casting method is prevalent in making pipe fittings and various cookware.

Type #4 Vacuum Die Casting

As the name suggests, this casting method involves creating a vacuum environment. It does this before inserting the molten metal. As a result, you don’t get any casting defects caused by trapped gas inside.

Vacuum die casting is suitable for making delicate components. Electronic castings, aircraft parts, and some automotive parts are noteworthy examples.

Type #5 Squeeze Die Casting

Squeeze die casting combines casting and forging. After injecting the molten metal inside the mold, the process applies high pressure during solidifying. Squeeze pressure mainly reduces the porosity defects.

Squeeze die casting is widely popular because of the high strength and density of the metal parts. Some common examples are suspension parts, brackets, and some building components.

Type #6 Semi Solid Die Casting

This process also combines casting and forging. The only difference is that this process uses semi-solid metals. It looks like a slurry consistency. SMDC is highly popular for making many car parts, electronic housing, and medical devices. go to simi solid aluminum die casting pagina voor meer informatie.

What is Die Casting Mold?

The tool used in the die-casting method is generally called a die-casting mold. People also call it a die-casting tool. The process of making this tool is known as die-casting tooling.

The definition says that a die-casting mold is a unique tool used in the die-casting process. Its primary purpose is to shape molten metal into desired forms. In most cases, they generally come with two halves: the fixed and moving die half.

When both halves are closed, they form a cavity inside that mimics the desired part’s shape. A high-quality die-cast mould is essential to ensure the highest accuracy of your finished metal parts. However, there are several components:

Mold Cavity

The hollow space inside a Mold is generally the mold cavity. It actually gives the shape and size of the final metal part. The molten metal is injected into this cavity and solidifies to get the desired form. Note that you must ensure high precision when making this cavity.

Core Pin Die Casting Mold

The core is another vital component of a die-casting mold. It creates features in casting, such as holes or recesses. It mainly creates complex geometries within the metal part. However, depending on the requirements, you can make it using sand or metal. Note that this core must withstand high pressure and temperature during operation.

Ejector Pins

As the name implies, these pins basically eject the movable die-cast mold half from the fixed one. During the design process, engineers carefully place them where they can apply even pressure. The correct design always ensures that the part is not damaged.

Runner-systeem

The runner generally channels the molten metal into the mold cavity. It consists of several tracks that go to different parts of the mold. Proper runner system design is crucial for even distributing molten metal. Overall, an adequate runner system significantly reduces defects.

Overflow System

The overflow system collects excess molten metal during the injection process. As a result, the system can prevent defects caused by trapped air. Note that this system may not be present for some die-casting molds.

Others

Elements like bolts and pins hold the die-cast mold system together. These parts need to be strong and carefully machined. The die-casting method requires high pressure, gas pressure, and heat. Choosing the right materials is crucial to keeping these parts in good shape.

Die Casting Mold Material: Hardened Tool Steel

Hardened tool steel is a general type of steel. It has various grades suitable for specific use. You can achieve steel’s high hardness and strength by the heat-treatment method. However, why are these tool steels so popular?

First, they offer high wear resistance. Second, their toughness usually makes them ideal for many machining jobs. Third, they also give stable dimensions. Finally, and most importantly, they can withstand extreme heat. As you know, this property is crucial for die-casting jobs.

Hardened tool steel has five different groups. Each group is ideal for unique applications.

Cold-working Die Casting Mold Material

The following four grades are widely prevalent in die-casting mold manufacturing.

Cijfer Koolstof Manganese Silicium Chromium Nickel Molybdenum Vanadium
O6 1.45% 1.00% 1.00% 0.8-1.4%
A3 1.25% 0.50% 5.00% 0.30% 0.9-1.4% 0.8-1.4%
A6 0.70% 1.8-2.5% 0.9-1.2% 0.30% 0.9-1.4%
D2 1.50% 0.45% 0.30% 11.0-13.0% 0.90% 1.00%

die casting mold equipment

Hot-Working Die Casting Mold Materials

As the name suggests, these materials are subjected to high temperatures during casting. They are ideal for HPDC die-casting molds. There are various grades: Grades H1 to H13 are usually chromium-based alloys. On the other hand, tungsten alloys are from H20 to H39, and molybdenum-based alloys are from H40 to H59.

Other types

There are other types of die-casting mold steels as well. SKD61, 8407, DIN 1.2343, 2083, and 8418 are noteworthy. These steels offer specific properties. As you know, die-casting methods have different types. Therefore, materials also vary based on these types.

Three Common Types of Die Casting Mold

We can generally divide molds into three types based on the number of cavities. This diversity mainly arises due to specific needs. Different cavity designs allow die-cast mold makers to produce parts rapidly.

Type #1 Single-cavity Dies

As the name suggests, these die-cast molds have a single cavity. Using these dies, you can produce one metal part per cycle. People widely use these molds for simple and low-volume orders.

Using these dies makes design easier, which is their main advantage. However, the speed of output is slower than with multi-cavity dies.

Type #2 Multi-cavity Dies

Multi-cavity dies have more cavities. Using these dies, you can produce multiple metal parts per cycle. This means you can produce more products than single-cavity dies. Therefore, multi-cavity dies are ideal for high-volume orders.

The best thing about these dies is that they offer cheaper production costs. However, they usually have complex designs.

Type #3 Family Molds

In multi-cavity dies you will find the same cavity design but multiple times. You can generally create multiple metal parts per cycle. However, in family molds, these designs are different. So, in one sense, all family molds are multi-cavity molds, but all multi-cavity molds are not family molds.

Aluminum Die Cast Mold: Market Trends

The aluminum die-cast mold market will grow significantly in 2024. According to Persistence Market Research, this market was valued at $301.3 million in 2023. In the future, this sector is expected to grow steadily at 4.8% every year. Experts expect this market will reach up to $481.6 million in 2033.

How are Die Casting Molds Made?

In the preceding section, we have briefly discussed various die-casting methods and molds or tooling types. In this section, we will generally focus on how they are made. You will be familiar with the step-by-step process in every die-casting factory. So, you will know every step of making the molds whenever you plan to make unique metal parts. This is actually important for custom metal parts manufacturing.

Step #1 Designing the Mold

This step is perhaps one of the most important aspects of the process. Here, you will decide how you wish your metal part to appear and what steps will be involved in manufacturing it. Depending on the part’s design, the type of die-casting method must also be properly selected.

Two parameters are essential in this case: a dimensional analysis and a geometric perspective. The dimensional view informs you of how many cavities your metal part has. Which of the single-cavity or multi-cavity or family mold types is required? This design also makes it easy for you to determine the pressure and volume of the casting.

A geometric view that informs you of the level of complication of the metal part and your plan on how to open and eject it. However, it is very important to note the kind of parting line that is used here. You must ensure that this parting line will coincide with the mold opening direction.

Similarly, a die-casting company also considers other important aspects during this step. We will briefly discuss those in the next section.

Step #2 Choosing the Material

The die-casting method usually involves varying pressure and temperature. Therefore, you must select material that is highly compatible with these situations. In general, engineers use various types of tool steels here. In the previous section, we have discussed these tools steel in detail.

Step #3 Machining the Mold

Once your design and materials are ready, you must plan how to shape the die-cast mold. In this case, various machining methods play a crucial role. Engineers prefer CNC machines for making die-casting molds.

As you know, CNC machining offers exceptional precision. You can technically achieve tolerance up to 0.01mm. You have options like CNC milling, drilling, turning, boring, and more.

Step #4 Heat Treatment

Various heat treatments are very important in die-casting mold making. This step significantly improves the machined parts’ strength and durability. Besides, the process makes the mold more resistant to wear and tear.

Common heat treatment methods are quenching, tempering, annealing, and stress relieving. These methods typically ensure the die-cast mold performs well during die-casting.

Step #5 Finishing

After heat treatment, the new die-cast mold needs some finishing touches. These steps are crucial to ensure smooth surfaces and precise dimensions.

Finishing techniques may include polishing, grinding, and sandblasting. The main purpose of all these techniques is to give the die-casting mold parts smoother and better textures. As a result, they can achieve high tolerances.

Step #6 Assembly if necessary

There are times when you may need to make die-cast mold parts separately. When there are many parts, assembly must always be done carefully. The die-casting mold factory always checks to ensure the assembly is lined up correctly.

Step #7 Testing

Once all the steps above are done, die-cast mold manufacturers test these molds in the lab. They run tests to ensure the mold is in good shape and works correctly. These tests tell you that the molds are high-quality.

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Key Steps in Die Casting Mold Design

As mentioned in the last part, several key factors are considered when designing a die-casting mold. This section will mainly discuss those and discover why they are crucial in die-cast mold manufacturing.

Actual Part Design

Before making the die-casting mold, engineers create the part itself. For this job, they use various 2D and 3D drawing programs. In most die-cast mold factories, graphic designers typically use SolidWorks or AutoCAD.

During visual testing, you need 2D models. Engineers use this drawing to check the sizes after each stage of production. A well-designed part gives high-quality results. So, whenever you work with a manufacturer, make sure they have these plans before they start making the product.

Die Casting Injection Molding Type

This is a very important factor when making a die-casting mold. Usually, it changes the quality, strength, and finish of the finished part.

Based on this injection, there are six different types: HPDC, LPDC, Vacuum, and more.

When designing the injection type, several factors need to be considered. First, what type of metal are you working with? Second, did you consider parting lines, geometric views, and design details? Third, what is your expected production speed?

When you use the right injection type, the mold will always fill properly, and casting flaws will be less common. Also, the right pick cuts cycle time by a large amount. In general, you can get very good output.

Gate And Runner Design

The gate and runner channel molten metal into the die-casting mold and usually control the flow of the liquid. Proper design ensures smooth and efficient filling and reduces various types of casting defects.

Consider size, location, and shape when designing a gate and runner. The gate must be placed in the right place to minimize turbulence.

Die Casting Mold Base Design

The mold base typically supports and aligns all mold parts. When designing, ensure you have created a robust design. It provides the system’s overall stability.

You should consider the material and temperature here. The mold base must withstand high pressure and temperature. You should also check for proper alignment and fit.

Cooling System

The cooling system helps the mold solidify the molten metal. A proper cooling system typically improves production speed and part quality. However, inappropriate cooling can cause various casting defects. Therefore, ensure an appropriate cooling system when designing a mold.

There are different kinds of cooling systems. People often use water lines and cooling inserts. Cooling plugs are great for places that need to cool down quickly. When you design a mold cooling system, try to balance the heat across the mold.

Venting and Ejection System

The ventilation and ejection system mainly removes trapped air from the mold. The trapped air could either be created by mold or be there before the injection.

When designing a mold, place the vents at high points. In this case, you can use thin vents to avoid flash. Also, put the ejector pins in the right place to prevent damage.

Note that effective venting and ejection systems usually improve part quality. Overall, it reduces cycle times and production efficiency.

Simulation

Once you have considered all the factors above, the simulation shows you precisely what you have designed. Simulations can help you find flaws and issues with the flow of metal. Die-cast Mold Makers typically use software like MAGMASOFT, ProCAST, and Flow-3D.

Veelgestelde vragen

What metals are used in die casting?

In die casting, the common metals are aluminum, zinc, magnesium, lead, pewter, and copper. These metals are popular due to their low melting point. Besides, they also offer excellent casting properties, strength, and durability. Among all these metals, aluminum is the most popular. It is lightweight and has an excellent strength-to-weight ratio.

Is 4140 a tool steel?

Yes, LSS 4140 steel is a type of tool steel. This alloy offers excellent hardness, strength, and wear resistance. It is an excellent tool steel for most machining jobs. More specifically, you can find its use in various rotating components. For example, axles, drive shafts, gears, and spindles are noteworthy.

What kind of steel is used for die casting?

The kind of steel mainly varies based on the type of die-casting method. For HPDC die-casting molds, H series tool steels are widely prevalent. On the other hand, for LPDC or cold-working jobs, the O, A, and D series of steel tools are famous. Some special grades are also there, like SKD61, 8407, and 8418.

Samenvatting

Die casting is crucial for making many complex metal parts. You can create die-casting parts through various methods. HPDC and LPDC are the two most common methods you will use in a die-casting mold company.

Die-casting mold has three types:  single-cavity, multi-cavity, and family molds. Each type is suitable for specific production requirements.

Sincere Tech is een van de top 10 fabrikanten van mallen in China that offers plastic injection mold, die casting mold. This mold factory offers a wide range of plastic mold and die-casting services. Their customer service is also very fast. Feel free to contact us.

CNC-freesbewerkingsservice

Wat is CNC-frezen?

Kennis van wat is CNC frezen stelt u in staat het proces te begrijpen. Enkele onderwerpen die in deze blog worden besproken, zijn onder meer spindelsnelheden, voedingssnelheden, asbewegingen, G-codes en machinecontrollers. We zullen ook beschrijven hoe deze onderdelen samenwerken om als één geheel te functioneren. Er is veel precisie in CNC-frezen. Moet wat is CNC frezen 101 om meer te weten.

Hoe werkt CNC-frezen?

Procesoverzicht

CNC-frezen maakt gebruik van G-codes en M-codes. Dit beweegt de spindel. De tafel ondersteunt het werkstuk. Wat is CNC-frezen is essentieel om te leren. Het wordt gebruikt om het snijgereedschap te roteren. Ze maken nauwkeurige vormen.

Dit kan snijden met verschillende snelheden. RPM en invoersnelheid zijn enkele van de parameters die het reguleren. De X-, Y-, Z-assen bepalen het proces. Het produceert onderdelen met precisie. De bewegingen worden gecoördineerd door de controller van de machine.

Wat is CNC-frezen?

CNC-programmering

Het programma instrueert de CNC-frees over wat er gedaan moet worden. Dit gebruikt G-codes voor bewegingen. M-codes besturen hulpfuncties. Het gereedschapspad definieert de beweging van het snijgereedschap.

Het start en stopt. De spindelsnelheid is van belang. Ze voeren parameters in voor elke as. Dit zorgt voor nauwkeurige bewerking. Het wordt gebruikt voor het snijden om te controleren op fouten. CNC-controller ontvangt en interpreteert opdrachten.

Machinebewegingen

De bewegingen van de machines in CNC-frezen zijn nauwkeurig. Dit omvat de X-as, de Y-as en de Z-as. De spindel roteert. Het snijdt het materiaal. Lineariteit bestuurt het gereedschap.

Ze stellen voedingssnelheden en dieptes vast. Inputs worden aangestuurd door het bedieningspaneel. Dit zorgt voor nauwkeurigheid, wat leidt tot perfecte onderdelen. De servomotoren regelen de snelheid. CNC-frezen creëren nauwkeurige vormen.

Snijgereedschappen

Snijgereedschappen in CNC-frezen zijn belangrijk. Wat is CNC-frezen helpt u het beter te begrijpen. Dit maakt gebruik van frezen en boren. De gereedschapshouder bevestigt ze. Ze draaien snel. Het snijdt het materiaal.

Het wordt beïnvloed door parameters zoals RPM. Het fluitnummer is van belang. Dat heeft invloed op de spaanafvoer. De spindel grijpt het gereedschap stevig vast. Dit zorgt voor schone sneden. Eén gereedschap creëert verschillende vormen.

Wat zijn de belangrijkste onderdelen van een CNC-freesmachine?

Machineframe

Het frame ondersteunt alle andere componenten van een CNC-machine. Deze is sterk en stabiel. Ze vereisen een stevig fundament. Dit is gemaakt van metaal.

Sommige onderdelen omvatten rails, schroeven en bouten. Het zorgt voor de stabiliteit van de machine. Nauwkeurigheid is erg belangrijk in het CNC-freesproces. Dat betekent dat kleine fouten onderdelen kunnen ruïneren.

Het frame moet stijf zijn. Sommige frames zijn gemaakt van ijzer. Ze wegen veel. Frames kunnen verschillende vormen hebben. Dit helpt bij het ondersteunen van de machine. Frames moeten goed gebouwd zijn.

Spindel

De spindel is centraal bij CNC-frezen. Wat CNC-frezen is, is goed om te weten. Het draait snel. Dit kan oplopen tot vele RPM's als. Ze houden snijgereedschappen vast. Het zwaait op en neer. Dit maakt gaten. Spindels gebruiken lagers.

Deze verminderen de wrijving. Ze houden het koel. Spindelsnelheid is belangrijk. Hogere snelheden snijden sneller. Er zijn koelventilatoren nodig. Sommige spindels zijn elektrisch. Andere gebruiken lucht. Dit onderdeel is cruciaal. Daarom is het zorgvuldig gemaakt.

Bedieningspaneel

Het bedieningspaneel bedient de CNC-machine. Het heeft veel knoppen. Hier voert u opdrachten in. Schermen tonen instellingen. Ze helpen u het proces te volgen. Het paneel heeft een CPU. Het draait programma's.

Dit kan een touchscreen zijn. Bedieningselementen zijn zeer nauwkeurig. Inputs zijn in G-codes. Deze instrueren de machine wat te doen. Veiligheidsschakelaars zijn belangrijk. Het paneel moet eenvoudig te gebruiken zijn. Het maakt CNC-frezen mogelijk.

Asmotoren

Asmotoren transporteren de CNC-onderdelen. Wat CNC-frezen is, is interessant om te weten. Ze regelen de beweging in X-, Y- en Z-richting. Het maakt nauwkeurige bewegingen mogelijk. Dit kan tot microns zijn.

Ze gebruiken stappenmotoren. Deze zorgen voor een exacte besturing. De motoren zijn krachtig. Dit helpt bij hoeveelheden onderdelen. Motoren hebben koeling nodig. Ze kunnen heet worden. Dit betekent dat asmotoren betrouwbaarheid vereisen. Daarom zijn ze goed ontworpenEen goede opstelling is cruciaal.

Gereedschapswisselaar

De gereedschapswisselaar werkt erg snel. Het houdt meerdere gereedschappen vast. Dit kan automatisch. Het vermindert de uitvaltijd. Het is belangrijk dat gereedschappen scherp zijn. Het wisselt ze snel. Ze hebben sensoren. Dit zorgt voor een correcte plaatsing. De gereedschapswisselaar heeft een magazijn. Hierin worden de gereedschappen opgeslagen.

Het is cruciaal voor het verhogen van de productiviteit. Alle gereedschappen hebben een specifieke functie. Het wisselen ervan moet snel gebeuren. Het moet worden opgemerkt dat het hele proces volledig geautomatiseerd is. Het maakt CNC-frezen efficiënt.

CNC-freesbewerking

Onderdeel Functie Materiaal Veelvoorkomende modellen Belangrijkste specificaties Onderhoud
Machineframe Structurele ondersteuning Gietijzer, staal Haas VF-2, DMG MORI Gewicht: 2.000-3.000 kg Smering, reiniging
Spindel Draait snijgereedschap Gelegeerd staal BT40, HSK63 Toerental: 12.000-30.000 Lagerinspectie
Bedieningspaneel Gebruikersinterface Kunststof, metaal FANUC, Siemens Scherm: 10-15 inch Software-updates
Asmotoren Stuurt assenbeweging aan Aluminium, staal NEMA 23, Servomotoren Koppel: 2-10 Nm Uitlijningscontroles
Gereedschapswisselaar Schakelt snijgereedschappen Staal, aluminium Paraplu, Carrousel Capaciteit: 10-30 gereedschappen Pneumatische controles

Tabel met de belangrijkste onderdelen van een CNC-freesmachine!

Welke materialen kunnen worden gefreesd met CNC-machines?

Metalen

CNC-frezen vormen metalen zoals staal en aluminium. Het heeft een spindel die roteert met 8000 RPM. De nauwkeurigheid van deze machine is 0,001. De gereedschapskop vertaalt in de X-, Y-, Z-richtingen.

Ze kunnen wisselen tussen gereedschappen. Dat bespaart tijd. De koelvloeistof houdt de temperaturen laag. Spaanders komen van het werkstuk. CAD-bestanden worden gebruikt als referentie.

De besturingseenheid van de machine volgt het programma. Dit maakt complexe vormen. Het metaal ontwikkelt gladde randen. Een bankschroef houdt het strak. De spindelsnelheid is eigenlijk een belangrijke factor. Het laatste gedeelte is goed.

Kunststoffen

CNC-frezen vormt ook kunststoffen. De spindel draait heel snel met 12000 RPM. Het gebruikt bits voor verschillende sneden. Ze bewegen in drie dimensies. Dit creëert nauwkeurige onderdelen. Het materiaal wordt vastgezet met klemmen.

De besturingseenheid scant het CAD-bestand. Dat begeleidt elke snede. Spaanders worden in een vacuüm gebracht. Het gereedschap wordt door de machine gekoeld. Het voorkomt smelten. Kunststoffen krijgen nette vormen. De tafel houdt het waterpas. Moet PEEK CNC-bewerking om meer te weten.

Het snijden gebeurt met een gereedschap dat bekend staat als de eindfrezen. Ze maken schone randen. Het is snel en precies. Het plastic onderdeel is klaar.

Composieten

Het is bekend dat composieten worden gefreesd door CNC-machines. De spindel draait met een snelheid van 10.000 RPM. De gereedschapsbits snijden lagen. Het beweegt ook op alle drie de assen. De werkvloeistof in de machine koelt het.

Het leest het CAD-bestand voor vormen. Dit maakt complexe ontwerpen. Spaanders worden door lucht verwijderd. De bankschroef houdt het op zijn plaats. De besturingseenheid werkt volgens het programma. Het wisselt automatisch van gereedschap.

In deze fase krijgt het composiet gladde randen. Het proces is efficiënt. Het produceert sterke en lichtgewicht componenten. De tafel beweegt nauwkeurig. Het laatste deel wordt gedetailleerd beschreven.

Hout

De houtsnijwerken die met CNC-frezen zijn gemaakt, zijn glad op het hout. Wat is CNC-frezen kan meer uitleggen. De spindel draait met 7.500 tpm. Bits zijn verschillend voor verschillende sneden. Ze bewegen in X-, Y-, Z-richting. Het hout wordt stevig samengeperst. De besturingseenheid werkt op basis van CAD-bestanden. Het begeleidt elke snede.

Het vacuüm ruimt spanen op. Koelmiddel heeft de functie om het gereedschap te koelen. De machine werkt en vormt nauwkeurige vormen. De tafel beweegt nauwkeurig. Dit zorgt voor nauwkeurigheid. De freeskoppen snijden zeer goed.

Ze maken schone randen. Het houten gedeelte lijkt schoon. Zo freest CNC hout. Het proces is snel.

Keramiek

Keramiek kan ook worden gefreesd met behulp van CNC. De spindel draait met 6.000 RPM. Er worden bits met diamantpunten gebruikt. Ze werken langs drie dimensies. De koelvloeistof voorkomt scheuren. Met andere woorden, het CAD-bestand regelt de werking van de machine. Dit maakt ingewikkelde vormen. Spaanders worden verwijderd door lucht.

De bankschroef zorgt voor de stevige positionering van het keramiek. De besturingseenheid schakelt gereedschappen. Het is in overeenstemming met het programma tot op de letter. De machine produceert scherpe randen. Het maakt sterke, gedetailleerde onderdelen.

De tafel beweegt nauwkeurig. Het keramiek blijft koel. Ze maken het af met aanrakingen. Het onderdeel is duurzaam.

Welke soorten CNC-freesmachines zijn er?

Verticale freesmachines

CNC-frezen maakt gebruik van verticale bewerking met X-, Y- en Z-bewegingen. Deze machines zijn uitgerust met een spindel en een motor. De spindel gaat ook omhoog en omlaag. Deze wordt aangestuurd door G-code. Dit type machine heeft een tafel eraan bevestigd. De tafel ondersteunt het werkstuk. Ze gebruiken een frees om materialen te snijden.

Deze opstelling zorgt voor nauwkeurig snijden. De snelheid kan worden ingesteld op maximaal 1200 RPM. Factoren zoals diepte en voedingssnelheid zijn belangrijk. Verticale freesmachines zijn nauwkeurig in hun werking. Ze zijn ideaal als het gaat om ingewikkeld werk.

Horizontale freesmachines

CNC-frezen omvat horizontale machines. Ze hebben een spindel die horizontaal loopt. De spindel draait met 1500 rpm. Het gebruikt vlakfrezen voor het snijden van materialen. Deze machine heeft beweging langs een X-as.

De Y-as is handig voor links- en rechtsbewegingen of shifts. Het werkstuk wordt op de tafel geplaatst. Ze verwerken grote taken. Dit kan gemakkelijk diepe sneden maken. De snelheid en voedingssnelheid van de machine zijn erg belangrijk. Horizontale freesmachines zijn krachtig. Daarom worden ze vaak gebruikt.

Meerassige freesmachines

CNC-frezen gebruikt meerdere assen in zijn bewerkingen. Ze werken met XYZ en A, B-assen. De spindel draait op verschillende manieren. Dit maakt complexe sneden mogelijk. Het heeft een bedieningspaneel. Het bedieningspaneel bepaalt de waarden. Voor precisie gebruiken ze kogelomloopspindels. Dit helpt bij verfijningsactiviteiten.

De snelheid van de machine kan 1800 rpm zijn. Het werkstuk draait op een draaitafel. Multi-assige freesmachines zijn geavanceerd. Ze bereiken ingewikkelde ontwerpen. Dit is goed voor gedetailleerd werk.

Portaalfreesmachines

CNC-frezen bestaat uit portaalmachines. Ze hebben een vaste brug. De spindel vertaalt zich op het portaal. Deze opstelling biedt stabiliteit. Het omvat een krachtige motor. De motor draait op 2000 tpm.

Deze machine werkt met grote werkstukken. De X-as en Y-as zijn breed. Ze gebruiken freeskoppen voor het snijden en deze freeskoppen zijn van zware aard. Het bedieningspaneel verandert de instellingen. Portaalfrezen zijn sterk. Ze voeren zware taken uit. De precisie is ongeëvenaard.

Bedfreesmachines

CNC-frezen heeft machines van het bedtype. Wat is CNC-frezen beantwoordt veel vragen. Ze bevatten een vaste spindel. De tafel vertaalt zich langs de X-as. Het zorgt voor stabiliteit. Het spindeltoerental is 1600 tpm.

Deze machine gebruikt een kogelomloopspindel voor nauwkeurigheid. Het is geschikt voor gebruik met zware materialen. Ze kunnen grote taken aan. De tafel wordt gebruikt om het werkstuk te ondersteunen. Dit maakt nauwkeurige sneden mogelijk. Het bedieningspaneel specificeert waarden. Bedfrezen zijn betrouwbaar. Ze voeren robuuste bewerkingen uit.

Hoe kiest u de juiste CNC-freesmachine?

Aanvraagvereisten

Bij CNC-frezen worden G-codes gebruikt om de beweging van de spindel te vertalen. Het vereist precisie. X-, Y- en Z-assen werken. Dit gereedschap wordt gebruikt voor het snijden van metalen of kunststoffen. De spindel draait snel. Cijfers zoals 3000 RPM zijn belangrijk. CAM-software helpt bij het plannen. Voedingssnelheid en diepte kunnen een verschil maken.

Ze moeten de uit te voeren taak aanvullen. Dat houdt onderdelen nauwkeurig. FANUC- of Siemens-controllers regelen het proces. Ze zijn cruciaal. Andere snijmachines zijn onder andere kogel- of platte eindsnijders. De orders worden met precisie door de machine uitgevoerd.

Materiaalcompatibiliteit

Er moet ook aan worden herinnerd dat verschillende materialen verschillende omgevingen vereisen. CNC-frezen past zich aan. Ze gebruiken codes om te bepalen waar ze moeten snijden. Dit is essentieel. Roestvrij staal vereist lage voedingssnelheden. Het houdt gereedschappen veilig. Aluminium maakt snellere sneden mogelijk. De hardheid van het gereedschap is van belang.

Er zijn verschillende soorten frezen voor het hout. De spindelsnelheid moet daarom proportioneel zijn aan het materiaal dat bewerkt wordt. CAM-software neemt de juiste beslissing. Smeermiddelen worden gebruikt om onderdelen te koelen. Dat helpt schade te voorkomen. Factoren zoals koppel en vermogen spelen een rol bij het proces.

Precisiebehoeften

Nauwkeurigheid is erg belangrijk bij het gebruik van CNC-frezen. Wat is CNC-frezen legt er meer over uit. Microns worden door machines gebruikt voor nauwkeurigheid. Het gereedschap volgt G-code. Het moet exact zijn. Lineaire encoders helpen bij het bepalen van beweging. Dit zorgt voor nauwe toleranties. Contrasterende assen moeten in harmonie zijn.

Kogelomloopspindels en geleiders helpen hierbij. Dat houdt fouten klein. Nauwkeurigheid is een cruciaal kenmerk van de controller, omdat het de behaalde resultaten bepaalt. Functies zoals spelingscompensatie helpen hierbij.

Ze garanderen het juiste pad van het gereedschap. Ze moeten allemaal in harmonie zijn met het ontworpen onderdeel. Het controleren van metingen is belangrijk.

Productievolume

CNC-frezen is geschikt voor verschillende volumes. Zowel kleine tot middelgrote productievolumes als grootschalige productie kunnen worden uitgevoerd. Dit heeft invloed op de instellingen. Ze gebruiken dezelfde G-codes. Ze gebruiken beide dezelfde G-code. Gereedschapswisselingen zijn geautomatiseerd. Palletwisselaars helpen bij het versnellen.

De capaciteit van de machine is van belang. Dit bepaalt hoeveel onderdelen er worden geproduceerd. CAM-software optimaliseert paden. Cyclustijd is cruciaal. Dit geeft aan hoe lang het duurt voor een bepaald onderdeel. De snelheid kan variëren, afhankelijk van de gebruikte materialen. Volumetrische taken vereisen sterke instrumenten.

Budgetbeperkingen

CNC-freeskosten variëren. De initiële machineprijs is van belang. Dit omvat controllers en spindels. Elk model heeft zijn eigen prijsklasse. Onderhoudskosten zijn doorlopend. Items zoals gereedschappen en koelmiddelen maken deel uit van de totale kosten. Ze moeten worden overwogen. Efficiëntie bespaart geld. CAM-software helpt. Het vermindert afval.

Verminderde snijsnelheid en voedingssnelheden leiden ook tot hogere kosten. Deze balans is essentieel. Upgrades kunnen kostbaar zijn. Het selecteren van de juiste machine zal op de lange termijn kosteneffectief blijken.

Prototype CNC-frezen

Wat zijn de voordelen van CNC-frezen?

Hoge precisie

Bovendien is CNC-frezen voordelig omdat het de creatie van zeer nauwkeurige onderdelen mogelijk maakt. Wat is CNC-frezen is goed om te weten. Deze machine heeft bewegingen die worden aangestuurd door G-code. Het kan snijden tot een dikte van 0,001 inch. Dat is superklein! De spindel kan roteren tot 30000 RPM.

Frezen en boren zijn enkele van de apparaten die worden gebruikt om de onderdelen de juiste vorm te geven. De tafel ondersteunt de onderdelen om ze stabiel te houden. De koelvloeistof houdt het koel. Dit voorkomt oververhitting.

Het is handig voor het maken van kleine componenten zoals tandwielen en bouten. Ze passen allemaal precies bij elkaar. CNC-frezen is geweldig voor nauwkeurig werk.

Herhaalbaarheid

De herhaalbaarheid van taken bij CNC-frezen is nauwkeurig. Dat betekent dat het constant onderdelen produceert. Deze machine gebruikt coördinaten in zijn beweging. Dit volgt doorgaans altijd dezelfde volgorde. Het gebruikt X-, Y- en Z-assen. De spindel is ingesteld op een specifiek aantal omwentelingen per minuut.

Snijgereedschappen zoals vlakfrezen en tappen snijden onderdelen. Ze houden alles hetzelfde. De tafel ondersteunt elk stuk op zijn plaats. Dit zorgt ervoor dat er geen beweging is. Consistentie is belangrijk voor grote hoeveelheden. CNC-frezen is hiervoor de beste optie!

Efficiëntie

CNC-frezen produceert onderdelen snel en nauwkeurig. Wat is CNC-frezen helpt u te begrijpen hoe. Deze machine begint met CAD-bestanden. Het gebruikt hogesnelheidssnijgereedschappen zoals kogelmolens en ruimers. Het heeft invoer- en snelheidsinstellingen. De spindel kan 24/7 draaien. Het blijft koel werken met behulp van koelmiddel.

De tafel beweegt snel. Dat scheelt veel tijd. Al deze onderdelen zijn sneller klaar. Dit kan helpen om veel stukken in korte tijd te maken. Efficiëntie is erg belangrijk. Ze maken veel dingen snel. CNC-frezen is geweldig!

Flexibiliteit

CNC-frezen heeft de mogelijkheid om gemakkelijk van de ene taak naar de andere te schakelen. Het kan veel soorten vormen en maten maken. Deze machine scant CAD/CAM-ontwerpen. De spindel heeft accessoires zoals fly cutters en boorkoppen. Het laat zien dat de tafel kan worden aangepast voor verschillende onderdelen.

Dit helpt om snel van baan te wisselen. Het gebruikt verschillende materialen zoals metaal, plastic en zelfs hout. Al deze worden netjes gehakt. De software verandert gereedschapspaden. Flexibiliteit is het vermogen om nieuwe dingen te doen. CNC-frezen voert veel taken uit. Dat is superhandig!

Lagere arbeidskosten

Werkkosten worden verlaagd door CNC-frezen. Wat is CNC-frezen vertelt u meer. Deze machine werkt grotendeels zelfstandig. Het werkt met NC-code. Veel gereedschappen worden aangestuurd door de spindel, zoals afschuinfrezen en sleufboren. De tafel beweegt zonder enige assistentie. Dit betekent minder werknemers.

Het blijft lange uren werken. Koelsystemen zorgen ervoor dat het goed draait. Ze zijn kosteneffectief en tijdbesparend. Deze machine voert veel taken uit. Minder arbeidskosten zijn altijd goed. CNC-frezen vermindert kosten en tijd!

Conclusie

Weten wat is CNC frezen toont zijn nauwkeurigheid. Het gebruikt G-codes, spindels en invoersnelheden. Voor meer details, bezoek PLASTICMOLD. CNC-frezen maakt het mogelijk om nauwkeurige componenten te creëren. Ontdek hoe CNC-machines voor u kunnen werken.

 

beste prijs voor cnc-gefreesde ptfe-onderdelen

The research and development in the fields of polymer chemistry and material science was significant in the mid of twenty century. The plastics and polymers were created as a result of this research and development. These materials had the capability to withstand higher temperatures. Polyphenylene sulfide and Polytetrafluoroethylene were initially created which proved to face and withstand higher temperatures as compared to traditional plastics. The aerospace industry raised significant demand and requirement of high temperature polymers or plastics in the 1970s.The efforts which were exerted because of the requirement of lightweight materials, bearing outstanding mechanical and thermal characteristics then resulted in the creation of the polymers like numerous types of polyamides and polyetheretherketone.

Ultimately metal parts of air craft engines and its structural components were replaced by these light weight and high temperature resistance plastics. The conventional plastics tends to get soften at high temperatures and then start to degrade at these elevated temperatures. While on the other hand high temperature plastics keep their properties intact at elevated temperatures and are considered suitable to be used in industries where extreme operating conditions exist. These properties include chemical resistance, dimensional stability and mechanical properties which are vital to performance of high temperature plastics. These high temperature plastics which are engineered to face and withstand high temperatures in extreme environments are also called engineering thermoplastics or high performance thermoplastics.

Hoogtemperatuur kunststof materiaal

 

Defining the High Temperature Plastic Material

High temperature plastic matreial is the material which is specially designed to be operated at high temperatures and withstand these elevated temperatures. The basic feature which is of importance is that high temperature plastics maintain their structural integrity and their mechanical properties at high temperatures. These high performance engineering plastics keep their original shape and do not deform while operating at elevated temperatures.

Depending upon the category of the plastics, they maintain their characteristics between the temperature ranges from 150°C to above 300°C.These high temperature plastics find their utilization in high temperature applications where normal plastics would degrade and deform and cannot sustain that high temperature. It is pertinent to mention that metals bear high weight and metals are also susceptible to corrosion. Keeping that in view high temperature plastic materials replace meals in such applications being light weight and corrosion resistant.

High temperature polymers and high temperature plastics (Differentiation)

The variation in composition and structure differentiate plastics and polymers. High temperature polymers are a vast category while high temperature plastics are subset of this broader category. High temperature polymers are comprised of both thermoset and thermoplastics. Advanced polymerization methods are applied to synthesize these polymers. Most of the times specific reinforcements or additives are utilized to increase their performance against high temperatures.

However, high temperature plastics are only comprised of thermoplastics. These plastics are designed to face and sustain elevated temperatures without deforming. These plastics offers very little or no degradation at high temperatures. These plastics are specifically engineered to keep their chemical resistance, mechanical properties and dimensional stability high temperature environment.

What Are the Materials of High Temperature Plastics (characteristics and Applications)?

Followings are the materials which fall in the category of high temperature plastics.

  1. Polytetrafluoroethylene (PTFE)

This material which is also termed as PTFE is excellent electrical insulator and is extensively utilized in applications where electrical insulation is required. This material is also used for non stick coating especially in cookware and in seals and bearings. This utilization is based on some prominent properties of this material as follows.

  • High temperature stability
  • Low friction coefficient
  • Goede chemische bestendigheid
  1. Polyfenyleensulfide (PPS)

This PPS material is a thermoplastic which has semi crystalline structure and exhibits following important characteristics.

  • Flame retardency (inherent)
  • High temperature resistance
  • Chemical resistance
  • Dimensional stability

These characteristics made this material suitable to be utilized in industrial applications. This material is also utilized in electrical and electronics sector in production of housings and connectors. Moreover in automotive industry this material is used to manufacture under the hood components. Go to PPS-spuitgieten to know more about this material.

spuitgegoten thermoplast

  1. Liquid crystal polymer (LCP)

This material which is also referred as LCP finds its applications in the following areas.

  • Telecommunication sector
  • Electronics industry (switches and connectors manufacturing)
  • Automotive industry (production of under the hood components)

This material bears the following significant properties which enable these materials to be utilized in above mentioned applications.

  • Excellent chemical resistance
  • High mechanical strength
  • Good dimensional stability
  • Excellent stiffness
  1. Polyetheretherketone (PEEK)

This material is also thermoplastic having semi crystalline structure and is also termed as PEEK. This material exhibits following characteristics.

  • High strength to weight ratio
  • Good mechanical properties
  • Excellent chemical resistance
  • Stability at elevated temperatures up to 250°C

Keeping in consideration of above mentioned properties of PEEK, it is extensively utilized in the following applications for manufacturing f the components which demands resistance to extreme environmental conditions and good mechanical strength. Go to peek plastic spuitgieten om meer te weten.

  • Semiconductor industry
  • Automotive sector
  • Aerospace industry
  • Medische sector
  1. Polyetherimide (PEI)

This material which is also called PEI provides followings important properties.

  • Flame resistance
  • Good mechanical strength
  • High thermal resistance
  • Excellent dimensional stability
  • Good electrical properties

Major applications of this material cover the following sectors.

  • Medical sector (manufacturing of sterilizable surgical instruments)
  • Automotive industry
  • Electronics industry
  • Aerospace sector
  1. Polyimides (PI)

Ployimides material which is also termed as PI offers following characteristics.

  • Good mechanical properties
  • Excellent thermal stability up to 400°C
  • Goede chemische bestendigheid
  • Low thermal expansion

This material is extensively utilized in the electronic industry, aerospace sector and automotive industry for following applications.

  • Electrical insulation
  • Thermal shields
  • Engine parts and spares
  • Circuit boards
  1.  Fluoropolymers (FPE)

The high temperature plastic materials which fall in this broader category are as follows.

  • Fluorinatedethylenepropylene
  • Polytetrafluoroethylene
  • Perfluoroalkoxy

These polymers tend to show certain qualities described as follows.

  • Elevated temperature stability
  • Excellent chemical resistance (against acids, bases and many solvents)
  • Low friction coefficient

These materials find their applications mainly in the following applications.

  • Wire coatings
  • Semiconductor processing
  • Tubing
  • Seals
  • Linings
  • Chemical processing equipment

  8.Polyphenylsulfone (PPSU)

PPSU is a thermoplastic, high-temperature engineering plastic part that was discovered in the 1960s. Their density is 1.24 g/cm2, water absorption is 0.22%, shrinkage rate is 1.007 (0.7%), melting temperature is 190 °C, heat distortion temperature is 1.82 MPa at 174 °C, and long-term use temperature ranges from -100 °C to +150 °C. This is one of the highest-quality plastic materials among them.

Simple molding process for PPSU plastic material

Pre-drying: PPSU needs to be pre-dried before processing to remove moisture in the material and prevent hydrolysis reactions at high temperatures. The drying temperature is 90℃–110℃, at least 3–4 hours of drying time.

Preheating: PPSU needs to be preheated before injection molding to improve the fluidity of the material. The preheating temperature is usually between 80 and 120 °C.

Injection: injecting PPSU into the mold. Injection pressure and speed need to be determined according to the type and injection molding wall thickness.

Cooling: This is pretty much the same as other injection molding parts, but PPSU needs a higher mold temperature than ABS or PC material, so normally the cooling time will be a little longer, but this depends on the wall thickness of the molding part.

Ejection: Once the PPSU-spuitgieten parts have completely cooled in the mold cavity, the mold opens, and the ejector system ejects the molded part out of the mold.

Post-processing: some parts may need some post-manufacturing, such as machining, CNC turning, cleaning, etc., depending on the customer’s requirements.

Application of PPUS molding parts,

PPUS is very expensive and is normally used in electrical appliances, electronics, medical industries, baby bottles, instruments, and aerospace departments for heat-resistant, corrosion-resistant, high-strength parts and insulation parts, industrial films, etc.

Below table are some of high temperature materials for your reference, if need high temperature plastic molding parts, you are welcome to contact us.

Karakteristiek ASTM Testing PTFE PFA FEP ETFE PCTFE PVDF KIJKJE PPSU PPS
Smeltpunt (Approximate  Tem:C) 327 308 270 260 211 175 343 250 278
Maximum continuous use temperature (20000 hours,Theoretical value:℃ 260 260 200 150 120 150 260 180 240
Thermal conductivity C177(( W/cm·k).℃/cm) 0.25 0.25 0.25 0.24 0.21 0.13 0.66 0.45 0.5
Hardness (shore) Shore D hardness tester D50-D65 D60 D55 D70-D75 D80 D75-D85 D85 D85-95 D87-95
Tensile Strength (Mpa) D638 25-40 28-35 20-25 40-50 32-40 40-58 98 – 100 94-100 >150
Compressive strength (Mpa) D695/1% Distorsion,25°C 5-6 5-6 5-6 11 9-12 13-14 25-35 95 27-134
Elongation (%) D638 250-450 300-400 270-330 400-450 90-250 300-450 40-50 60-120 200
Impact strength (J/m) D256 160-170 no breaking no breaking no breaking 135-145 1105 40-50 690 800
Proportion D792 2.13-2.22 2.12-2.27 2.12-2.27 1.70-1.86 2.10-2.14 1.76-1.78 1.26 – 1.32 1.32-1.5 1.32-1.5
Krimppercentage (Theoretical value) 2%-5% 4% 3%-6% 3%-4% 1.5%-2% 1.40% 0.50% 0.50% 0.50%
Dielectric constant D150/106HZ 2.1 2.1 2.1 2.6 2.4 6.43 3.2 3.94 3.5
Electrical breakdown strength(MV/V) D149/shot time,3.2mm 19 20 20-24 16 20-24 10 25 6.3 17
Weather resistance excellent excellent excellent excellent excellent excellent excellent excellent excellent
Resistance to chemicals excellent excellent excellent excellent excellent excellent excellent excellent excellent
Flame retardancy, flame retardancy (%) Limiting oxygen index concentration >95 >95 >95 >31 >95 >43 >95 >95 >95

What Are The Processing Methods Of High Temperature Plastics?

Special techniques are used for processing of high temperature plastics. Moreover, during the processing it is make sure that characteristics of high temperature plastics including mechanical strength and heat resistance remain intact during the whole manufacturing operation.

The most common and extensively used processing methods for high temperature plastics are as follows.

  1. Compressievormen

In this process an open mold cavity is prepared. This mold cavity is then heated and a calculated amount of plastic is placed inside it. After that this mold is closed and an adequate pressure is applied onto the material. Application of this pressure compresses the material and the material is transformed into the required shape. The parts which are of large size and have complex geometries are molded by this method. These parts are difficult to be molded by other molding processes. The materials which are processed by compression molding method include polyetheretherketone, polyimides and thermoset high temperature plastics. Following parameters need to be controlled for producing uniform and defects free final product.

  • Temperatuur
  • Druk
  • Molding time
  1. Spuitgieten

In this processing method a mold cavity of desired shape is prepared first. After that the plastic material in molten form is injected into that mold cavity. This injection is carried out under high temperature and pressure. High temperature plastics are most commonly processed through injection molding. This processing method is feasible for high volume items and intricate shapes. The materials which are processed through injection molding consist of fluoropolymers, polyphenylene sulfide, polyetheretherketone and polyetherimide. The parameters which are required to be controlled to avoid warping and to achieve dimensional stability are as follows:

  • Cooling rates
  • Temperatuur
  • Mold material resistance to corrosive environment
  • Mold material resistance to high temperature
  1. Extrusie

This method utilizes extrusion process to produce desired product or item. In this processing technique a permanent die of desired shape is utilized. The plastic material in molten form is forced into the die by using compressive force. As a result of this product of uniform cross section bearing continuous profile is produced. In order to avoid thermal degradation the control of extrusion temperature is critical.

In extrusion processing of high temperature plastics the quality of the extruded product and smooth flow of the material varies from material to material. So, die geometry and design of screws are adjusted to achieve the desired quality. The most common high temperature plastics which are commonly processed through extrusion method include thermoplastic composites, fluoropolymers, polyphenylene sulfide and polyetheretherketone. Following products are produced commonly through this processing method.

  • Tubes
  • Sheets
  • Rods
  • Profiles of high temperature plastics
  1.  Bewerking

This processing technique involves utilization of various machines and tools to shape the high temperature plastics. In this method most commonly used machines are CNC machines, milling machines and lathe machines. This kind of processing is applied on the products or items which have complicated geometries and are of low volume. This method demands special tooling and specialized techniques because of the resistance and toughness of the material. Check PEEK CNC-bewerking om meer te weten.

But still all kinds of high temperature plastics can be machined by using this technique. During the machining process of high temperature plastics a considerable amount of heat is generated. This heat is crucial to destabilize the dimensional accuracy of the item and also propagate the degradation of the material. In order to eliminate the adverse effects of this heat lubrication is carried out during the machining process.

  1. Additive Manufacturing

This processing method is very unique as compared to other processing methods. In this technique high temperature plastics are utilized in the form of filaments or powders. This powder is used to produce the parts layer by layer. This is carried out by adopting additive manufacturing techniques. Mainly there are two additive manufacturing techniques which are as follows.

  • Fused deposition modeling
  • Selective laser sintering

This process is feasible for producing prototypes. However, parts having complex geometries are also produced. This processing method offers minimal wastage of the material. There are numerous high temperature plastics which are compatible with additive manufacturing method. These materials include polyetheretherketone and polyetherimide. This method requires very accurate control of the process parameters in order to achieve demanded dimensional accuracy and mechanical properties. Moreover, special equipment is required for this processing method which can handle high temperature plastic materials.

High temperature plastics

Conclusie

Material science is touching new horizon and showing advancement because of high temperature plastics. These materials provide very unique and special properties including mechanical strength, elevated temperature stability and resistance to chemicals such as acids, basis and solvents. High temperature plastics materials have enabled the manufacturing of top notch performing spares and products which are strong, lighter and durable. Subsequently, all prominent sectors and industries have experienced revolution including electronics, automotive, medical and aerospace.

The conventional plastic materials cannot withstand high temperatures and experience degradation. However, high temperature plastics are very suitable for those applications because they have the prominent property to face elevated temperatures. Moreover, high temperature plastics show resistance to corrosion and mechanical stresses. These materials provides extended lifespan to products and spares because of their unique characteristics such as resistance to fatigue, keep dimensional stability and electrical insulation under extreme operating conditions.

High temperature kunststoffen are being more important day by day because industrial sector is demanding high performance of components and spares. Advance research and development in the fields of material science and processing methods is depicting that these materials can be utilized for higher requirements. This will result in increased efficiency, sustainability along with safety in numerous sectors.Top of Form

Kunststof spuitgietfaciliteit

De markt voor bedrijven voor kunststof spuitgieten in China is gegroeid en uitgebreid door de ontwikkeling van 3D-prototypeproductie. De markt was 36 miljard yuan in 2018 en steeg naar 45 miljard yuan in 2023, met een samengestelde jaarlijkse groeivoet (CAGR) van 6%. De afgelopen vijf jaar is deze met 9% gestegen. Deze groei zal naar verwachting aanhouden, waarbij de markt naar verwachting zal groeien tot 58 miljard yuan in 2030, met een samengestelde jaarlijkse groeivoet van ongeveer 5%.

De China Plastics Industry Association heeft de top 10 van kunststofspuitgietbedrijven in China in 2020 gerangschikt op basis van hun belangrijkste bedrijfsinkomsten.

Ontdek de top 10 van bekendste Chinese bedrijven voor kunststofspuitgieten.

Hier is de toplijst van 10 Chinese bedrijven voor kunststofspuitgieten die erkend worden voor het leveren van strenge kwaliteitsnormen aan hun gewaardeerde klanten over de hele wereld

1. Dongguan Sincere Tech Co., Ltd.

Chinees bedrijf voor kunststof spuitgieten

Jaar van oprichting: 2015

Locatie: De stad Dongguan ligt in de provincie Guangdong.

Industrie type: Vier processen die veel worden gebruikt bij de productie van auto-onderdelen zijn kunststof spuitgieten, spuitgieten, bewerken en oppervlakteafwerking.

Dongguan Sincere Tech Co., Ltd. is al meer dan 19 jaar actief en is gespecialiseerd in betaalbare, hoogwaardige mallen en onderdelen. Het bedrijf behoort tot de beste prime bedrijven voor kunststof spuitgieten in ChinaZe dekken ruimschoots de behoeften van verschillende industrieën, zoals de lucht- en ruimtevaart, de medische sector en de consumentenproductensector, door onderdelen van strenge standaardkwaliteit te leveren.

Belangrijkste kenmerken:

Klanttevredenheid wordt gewaarborgd door het ondertekenen van een geheimhoudingsverklaring en het leveren van kwalitatieve aftersalesservice.

Transparantie in diensten: Klanten krijgen uitgebreide informatie over de gebruikte grondstoffen en de resultaten van de tests die op de producten zijn uitgevoerd, waardoor vertrouwen en openheid ontstaat. Ze bieden ook betaalbare prijzen die binnen het bereik van elke klant vallen.

Producten en diensten:

  • Elektronica, huishoudelijke apparaten, opbergmiddelen, haarverzorgingsproducten, medische apparatuur, etc.
  • Meubelsjablonen, sjablonen voor babyproducten en sjablonen voor auto-onderdelen.
  • Kunststof spuitgieten, 3D-printen en insert molding.
  • Andere diensten die wij aanbieden zijn CNC-bewerking, overspuiten, aluminium spuitgieten, ontwerp van kunststofproducten en prototypeproductie.
Bedrijven voor kunststof spuitgieten

Dongguan Sincere Tech Co., Ltd. is een gerenommeerd malfabrikant in China. Het is gespecialiseerd in kunststofgieten en is toegewijd aan het leveren van hoogwaardige mallen en uitstekende diensten aan haar gewaardeerde klanten.

 

2. Seasky Medisch

Bedrijfstype: Fabrikant van oplossingen voor kunststof spuitgieten

Hoofdkwartier: De stad Shenzhen ligt in de provincie Guangdong in de Volksrepubliek China.

Jaar van oprichting: 1999

Certificeringen: ISO 10993, ISO 13485:2016 en ISO 8 Cleanroom

Seasky Medical is een vooraanstaande fabrikant van plastic mallen in China en is gespecialiseerd in de medische industrie. Ze bieden oplossingen in malontwerp, productie, materiaalselectie, spuitgieten en productontwikkelingsdiensten.

Seasky Medical is al meer dan tien jaar in productie en heeft 11 jaar extra ervaring van het moederbedrijf. Het is een van de zeldzaamste bedrijven in het medische spuitgietbedrijfsveld, wat het onderscheidt door het leveren van strikte kwaliteitsprototypes voor medisch gebruik aan de gezondheidszorg. Het bedrijf heeft een ISO 8 cleanroom-productievloer en gebruikt 10 ultramoderne spuitgietmachines en -apparatuur om hoogwaardige kunststof spuitgietmatrijzen te produceren. Seasky Medical is toegewijd aan het leveren van kwaliteitsnormen aan haar klanten, wat het een van de toonaangevende bedrijven in medisch spuitgieten heeft gemaakt.

3. JMT Automotive Mold Co., Ltd.

Soort bedrijf: Vormproductiebedrijf

Hoofdkwartier: Taizhou, Zhejiang, China

Jaar van oprichting: 2005

Certificeringen: ISO9001/TS16949

JMT Automotive Mold Co., Ltd. is een vooraanstaande professionele kunststof spuitgietbedrijf in China, gevestigd in Huangyan, provincie Zhejiang. Sinds de oprichting in 2005 heeft het bedrijf zijn klanten voorzien van standaardkwaliteitsproducten en uitgebreide diensten. Ze richten zich voornamelijk op automallen, SMC-mallen, mallen voor huishoudelijke apparaten en mallen voor huishoudelijke producten.

Hun fabriek beslaat 23.000 vierkante meter en is uitgerust met moderne apparatuur: hogesnelheidsfreescentra uit Taiwan, meer dan 10 Haïtiaanse spuitgietmachines, meerassige zoals vijfassige hogesnelheidsbewerkingscentra, coördinatendetectoren, uiterst nauwkeurige EDM-machines, materiaalhardheidsdetectoren en 50 CNC-bewerkingseenheden.

4. Dongguan Runsheng Plastic Hardware Co., Ltd.

Jaar van oprichting: 2007

Industrie Locatie: De provincie Guangdong is een van de provincies van de Volksrepubliek China.

Industrie: Productie

Dongguan Runsheng Plastic Hardware Company is een van de toonaangevende bedrijven in de Chinese kunststof spuitgietindustrie die zich richt op het ontwerpen en assembleren van mallen. Het bedrijf is opgericht in 2007 en wordt geleid door professionele managers en technisch personeel die zich inzetten voor het creëren van hoogwaardige, gediversifieerde producten.

Enkele van de belangrijkste diensten die zij aanbieden zijn: snelle prototyping-bewerking, spuitgieten, gereedschap, spuitgieten en CNC-bewerking. Dongguan Runsheng heeft een breed productportfolio, waardoor klanten oplossingen kunnen selecteren die aan hun vereisten voldoen.

5. Shenzhen Silver Basis Technology Co., Ltd.

Bedrijfstype: Industriële matrijzenbouw | Fabricage van motorvoertuigonderdelen

Locatie: Shenzhen, provincie Guangdong, China

Jaar van oprichting: 1993

Certificeringen: ISO9001:2008, ISO14001:2004

Shenzhen Silver Basis Technology Co., Ltd. is een van de toonaangevende professionele kunststof spuitgietbedrijven in China. Ze richten zich voornamelijk op precisiemallen en bieden gereedschaps- en gietdiensten voor structurele onderdelen en grote precisie spuitgietmallen. Het heeft samengewerkt met wereldwijde bedrijven zoals Peugeot-auto's en ZTE-mobiele telefoons.

Silver Basis Technology levert gespecialiseerde diensten voor de automobielsector. Het voorziet autofabrikanten van mallen voor grote auto-interieur- en exterieuronderdelen, functionele onderdelen en autobeveiligingssystemen.

Andere producten

Ze bieden ook metaalstansen en spuitgieten aan, evenals auto-onderdelen voor binnen en buiten.

Producttestdiensten, strenge kwaliteitsmallen en gefabriceerde onderdelen.

6. Rilong Mold Co., Ltd.

Jaar van oprichting: 1990

Locatie: Shenzhen, China

Industrie type: Productie

Certificeringen: ISO 9001:2015, ISO 14001:2015, IATF 16949:2016 en vele anderen

Rilong Mold Co. is een Chinees bedrijf dat mallen produceert en de reputatie heeft om zeer nauwkeurige plastic injectieproducten te leveren. Ze hebben een sterk personeelsbestand van 300 werknemers, gespecialiseerd in engineering, productie en testen. Rilong biedt een volledig assortiment van interne productiediensten die kunnen worden aangepast aan de specifieke vereisten van de klant. Hun portfolio omvat auto-onderdelen, optische producten, beveiligingscamera's en elektronica.

7. HT-mal

Jaar van oprichting: 2006

Locatie: Shenzhen, China

Type industrie: Productie

Certificeringen: ISO 9001:2015, ISO 14001:2015, IATF 16949:2016

HT Mould is een professioneel bedrijf voor kunststof spuitgieten in China dat in 2006 werd opgericht. Ze houden zich bezig met het ontwerpen van kunststof mallen, spuitgietmatrijzen en gegoten onderdelen voor verschillende sectoren van de economie. HT Mould heeft 450 professionele werknemers en heeft kantoren in verschillende regio's van de wereld, zoals Amerika, Rusland en Europa.

8. Richfield Plastics Ltd.

Zakelijke mogelijkheden: Fabrikant, Leverancier, Exporteur, Private Label

Locatie: Dongguan

Belangrijkste markten: Amerika, Europa en het Midden-Oosten.

Jaar van oprichting: 2001

Certificaten: ISO-certificering

Richfields Plastics Ltd. werd in 2001 opgericht als een bedrijf dat kunststof spuitgiet. Door de jaren heen is het bedrijf gegroeid en biedt het haar klanten complete oplossingen voor hun productiebehoeften, waaronder het vervaardigen van mallen.

Richfield Plastics is een mallenmaker en spuitgieter gevestigd in Dongguan, China. Het heeft een fabriek van 18.000 vierkante meter en 250 werknemers. Bovendien biedt het een verscheidenheid aan nabewerkingsservices en afwerkingsservices, waaronder spuitverven, printen, assembleren, verpakken en etiketteren.

In tegenstelling tot sommige concurrenten levert Richfields Plastics spuitgietmatrijzen en kunststofproducten aan diverse industrieën, waaronder de automobielindustrie, sportindustrie, consumentenproducten, rubber, speelgoed, huishoudelijke en keukenproducten en gereedschappen.

9. TK Mold (Holdings) Ltd.

Soort bedrijf: Leverancier van kunststof spuitgietoplossingen

Hoofdkwartier: Shenzhen is een stad in de provincie Guangdong, China.

Jaar van oprichting: 1983

Certificeringen: ISO 9001:2015, ISO 13485:2016, ISO 14001:2015, OHSAS 18001:2007

TK Mold Holdings Limited is een toonaangevend merk dat een reputatie heeft opgebouwd door unieke oplossingen voor kunststof mallen te bieden aan de medische en automobielsector. TK Mold werd in 1983 opgericht in Hong Kong en is al meer dan 40 jaar actief in de sector. Het is een professionele fabrikant van kunststof mallen en onderdelen voor medische apparaten, slimme huishoudelijke apparaten, mobiele telefoons en nauwkeurige elektronica. TK Mold is een bekend merk in China en Azië en heeft opmerkelijk succes geboekt; het is het eerste bedrijf in omzet onder Chinese MT3-level leveranciers, volgens IPSOS, een onafhankelijk marktonderzoeksbureau.

TK Mold bestaat momenteel uit vijf productielijnen: vier in Shenzhen en één in Duitsland. Het bedrijf heeft een groot productiegebied verspreid over meer dan 200.000 vierkante meter. Bovendien is TK Mold Holding een gerenommeerd bedrijf dat verschillende sectoren bestrijkt, waaronder telecommunicatie, automotive, elektrische apparaten, gezondheidszorg en digitale mobiele apparaten.

10. Eco Molding Co., Ltd

Soort bedrijf: Fabrikant van op maat gemaakte kunststof spuitgietproducten

Hoofdkwartier: Songgangstad, Shenzhen, China

Jaar van oprichting: 2008

Certificeringen: ISO 9001-2008

Medewerkers: 100 werknemers

Eco Molding Limited is een Chinees bedrijf dat gespecialiseerd is in de kunststof spuitgietindustrie. Het is al meer dan tien jaar actief sinds de oprichting in 2008. Eco Molding heeft zichzelf gevestigd als een toonaangevend bedrijf voor op maat gemaakte kunststof spuitgietproducten dat zijn diensten levert aan Noord-Amerikaanse en Europese markten met behulp van hardwerkende werknemers, kwaliteitsapparatuur en ervaren management.

Eco Molding richt zich op verschillende soorten plastic mallen en biedt spuitgietoplossingen voor elektronica, algemene industriële OEM-producten, huishoudelijke apparaten en de automobielindustrie. Het bedrijf handhaaft ook een hoog niveau van transparantie door zijn klanten directe fabrieksprijzen te bieden, wat helpt om vertrouwen en geloofwaardigheid op te bouwen.

Eco Molding Co. Ltd. heeft meer dan, beslaat een oppervlakte van meer dan 2.000 vierkante meter en heeft kapitaalgoederen van meer dan 8 miljoen RMB. Met dergelijke middelen heeft het bedrijf de capaciteit om maandelijks 40 tot 50 plastic spuitgietmatrijzen te produceren.

Bedrijven voor kunststof spuitgieten in China

Samenvatting

Momenteel zijn er veel bedrijven voor kunststof spuitgieten in China die gegoten kunststof stoelen, babyspeelgoed, huishoudelijke apparaten en andere consumentenproducten aanbieden tegen redelijke prijzen. Bij het kiezen van een bedrijf voor kunststof spuitgieten om mee te werken, is het belangrijk om aspecten zoals de kosten, betrouwbaarheid, duurzaamheid en functionaliteit van het product te overwegen. Alle bovengenoemde bedrijven kunnen u helpen uw visies tot leven te brengen, dus kies degene die aan uw behoeften voldoet. Als u op zoek bent naar op maat gemaakte on-demand productieoplossingen van topbedrijven voor kunststof spuitgieten of bedrijven voor kunststof spuitgieten bij mij in de buurt, zoek dan nergens heen. Neem contact met ons op om uw beoogde productproductieoplossing te vinden.

Spuitgietbedrijf

Chinese top 10 schimmelfabrikanten

Vormen is een proces van het vormen van vloeibare harsen of kneedbare grondstoffen door ze in een mal te gieten. De Chinese malfabrikanten hebben een aanzienlijke impact op de productie van talloze gegoten producten die onmisbaar zijn. Het selecteren van de juiste malfabrikant is echter geen gemakkelijke taak en op de een of andere manier een opschudding, omdat er in China veel opties zijn. Om uw zoektocht gemakkelijker te maken, hebben we een lijst gemaakt van de top 10 fabrikanten van mallen in ChinaDaarom hoeft u uw tijd niet doelloos op het web te surfen.

Bovendien hebben we een stijgende trend gezien in 3D-printen in India. Het is daar echter nog geen grote industrie, maar het vertoont binnenkort tekenen van groei. Dit artikel bevat informatie over fabrikanten van plastic mallen in China, hun belangrijkste producten en nog veel meer om over te weten.  

Top 10 matrijzenfabrikanten in China

Laten we de top 10 matrijzenfabrikanten in China eens bekijken.

1. Dongguan Sincere Tech Co., Ltd

China mal bedrijf

Jaar van oprichting: 2015

Locatie: Provincie GuangDong: stad Dongguan.

Industrie type: Kunststof spuitgieten, spuitgieten, bewerken en oppervlakteafwerking.

Sincere Tech bestaat al meer dan 19 jaar en levert de beste mallen en onderdelen tegen redelijke prijzen en hoge kwaliteitsnormen. Ze zijn gespecialiseerd in kunststof spuitgieten, waardoor ze zich onderscheiden om te voldoen aan verschillende industriële behoeften, van lucht- en ruimtevaart en medisch tot consumentenproducten.

Belangrijkste kenmerken:

Klanttevredenheid: Ze hechten waarde aan hun klanten door geheimhoudingsovereenkomsten en een uitstekende aftersalesservice te bieden, waarbij klanttevredenheid voorop staat.

Transparantie: Hun gewaardeerde klanten krijgen beschrijvingen van grondstoffen en producttestresultaten voor meer vertrouwen in de omgang met elkaar. Ook krijgt u een concurrerend prijsbudget op basis van uw behoeften binnen uw beperkte budget.

Producten en diensten:

  • Mallen voor elektronica, huishoudelijke apparaten, opbergsystemen, haarverzorgingsproducten, medische hulpmiddelen en meer.
  • Sjablonen voor meubels, babyproducten en auto-onderdelen.
  • Kunststof spuitgieten, 3D-printen en insert molding.
  • Andere diensten omvatten CNC-bewerking, overspuiten, aluminium spuitgieten, ontwerp van kunststofproducten en prototypeproductie.

Dongguan Sincere Tech Co. Ltd is een van de top 10 matrijzenfabrikanten in China die hoogwaardige kwaliteitsoplossingen levert in de kunststofspuitgietindustrie met kwaliteit en klanttevredenheid.

2. Bluestar Technology Group Co., Ltd.

malfabrikant China

Jaar van oprichting: 2003

Locatie: Guangdong, China

Industrie type: Productie van auto-onderdelen, onderzoek en ontwikkeling en gereedschappen.

Bluestar Technology Group Co., Ltd. is een spuitgietbedrijf in China dat al meer dan twee decennia actief is in de auto-onderdelenindustrie. Bluestar heeft een groot personeelsbestand van meer dan 800 werknemers en is een nationale en gemeentelijke hightechonderneming met ISO9001-, ISO14001- en IATF16969-certificeringen. Het bedrijf richt zich op het aanbieden van de beste auto-onderdelen en complete gietdiensten voor de auto-industrie.

Belangrijkste kenmerken:

Klanttevredenheid: Bluestar streeft ernaar om klanten de beste producten te bieden via haar sterke R&D- en productiesystemen.

Transparantie: Het bedrijf biedt gedetailleerde informatie over de grondstoffen en testresultaten van de producten om het vertrouwen van hun klanten te winnen. Ze bieden ook concurrerende prijzen die flexibel zijn om aan de budgetbehoeften van de klanten te voldoen.

Producten en diensten:

  • Productie van auto-onderdelen: omvat koplampen van voertuigen, interieurbekledingscomponenten, dubbelgegoten gietproducten (2K-producten) en luchtbehandelingssystemen.
  • R&D-centrum: houdt zich bezig met het ontwerpen en produceren van autoaccessoires, -onderdelen en -systemen.
  • Productiediensten: Bewerkingstechnologie voor het spuitgieten van nauwkeurige auto-onderdelen.

Bluestar Technology Group Co., Ltd. behoort tot de top 10 bedrijven voor kunststof spuitgieten in China dat kwaliteitsoplossingen levert in de auto-onderdelenindustrie en zich toelegt op kwaliteit, innovatie en klanttevredenheid.

3. TEC Schimmel Holdings Limited

fabrikanten van mallen in China

Bedrijfsnaam: TEC Mold Holdings Limited.

Jaar van oprichting: 2000

Locatie: Shenzhen en Dongguan, provincie Guangdong, China.

Industrie type: Spuitgietgereedschappen, kunststof spuitgieten, secundaire bewerkingen.

TEC Mold Holdings Limited werd opgericht in 2000 en is een Bedrijf gevestigd in China die een volledig scala aan productiediensten aanbiedt. TEC Mold is een betrouwbare leverancier van "one-stop manufacturing service" geworden met een productieoppervlak van 50.000㎡ en een team van meer dan 650 werknemers. Gecertificeerd volgens de ISO 9001:ISO/TS16949:2009-normen, wordt het bedrijf erkend als een hightechonderneming in China.

Belangrijkste kenmerken:

Uitgebreide faciliteiten: TEC Mold heeft vier fabrieken in Shenzhen en Dongguan met vier divisies: Precision Mold Shop, Large Mold Shop en Injection Molding met secundaire activiteiten.

Kwaliteitsborging: TEC Mold heeft aparte teams voor Kwaliteit, Projectmanagement, Ontwerp, Engineering en Productie om de kwaliteit van al haar processen te waarborgen.

Diverse marktpositie: Het bedrijf bedient verschillende sectoren, waaronder de automobielsector, de medische sector en gezondheidszorg, de lucht- en ruimtevaart, de elektronicasector, de huishoudsector, de telecommunicatiesector, de bouwsector en de beveiliging.

Producten en diensten:

  • Kunststof spuitgietgereedschap: Precisiegereedschap voor auto-onderdelen, medische apparatuur, huishoudelijke apparaten, vliegtuigonderdelen en andere producten.
  • Spuitgieten: Hoogwaardige spuitgietdiensten voor de industrie.
  • Secundaire werkzaamheden: Andere diensten zoals spuitverven, UV-coaten, assemblage, enzovoort.

TEC Mold Holdings Limited is een Chinees mallenbedrijf dat zich toelegt op het leveren van hoogwaardige productiediensten, innovatie en klanttevredenheid in verschillende sectoren.

4. Jabil Een

spuitgietmatrijs china

Bedrijfsnaam: Jabil Een

Jaar van oprichting: 1966

Locatie: Internationale activiteiten met meer dan 100 locaties in ruim 20 landen.

Industrie Type: ISpuitgietmatrijzen Productieoplossingen, Engineering, Supply Chain Management.

Jabil One is een wereldwijde leverancier van productieoplossingen die in 1966 is opgericht en momenteel op meer dan 100 locaties over de hele wereld aanwezig is. Jabil One is een bedrijf dat al meer dan 50 jaar actief is en een team van professionals heeft die zich inzetten om engineering-, productie- en supply chain-oplossingen aan hun klanten te leveren.

Belangrijkste kenmerken:

1. Wereldwijd bereik: Jabil One is wereldwijd actief met een breed scala aan schaalbare oplossingen die zijn afgestemd op de behoeften van klanten in verschillende sectoren.

2. Uitgebreide expertise: Het bedrijf combineert technische vaardigheden, ontwerpvaardigheden, kennis van de toeleveringsketen en wereldwijd productbeheer om de beste oplossingen te bieden voor de beste merken ter wereld.

3. Milieuverantwoordelijkheid: Jabil One streeft ernaar duurzame processen te creëren die milieuvriendelijk en verantwoord zijn.

4. Vooruitgang en uitmuntendheid: Jabil One wil alles mogelijk maken en alles beter maken in de wereld van de toekomst.

Producten en diensten

  • Geavanceerde assemblageoplossingen: de miniaturisering van elektronica en de convergentie van complexe technologieën.
  • Initiatieven voor de circulaire economie: duurzame materialen, modulair ontwerp en samenwerking met leveranciers voor ecologisch duurzame producten.
  • End-to-end productie: Wij bieden end-to-end productiediensten voor sectoren zoals de automobielindustrie, gezondheidszorg, consumentenelektronica en meer.

Jabil One is een wereldwijde leverancier van productieoplossingen voor kunststof spuitgieten. We werken samen met de meest innovatieve bedrijven ter wereld om succes te behalen, innovatie te stimuleren en een verschil te maken in het leven van mensen en de planeet.

5. DongGuan Wellmei Industrieel Co., Ltd.

China mal bedrijf

Jaar van oprichting: 1988

Locatie: Dongguan, provincie Guangdong, China.

 Industrie type: Spuitgieten van kunststofmallen, productie van kunststofproducten, oppervlaktebehandeling, assemblage en meer.

Wellmei Industrial Co., Ltd. is al meer dan 30 jaar een toonaangevende fabrikant van plastic mal-injectie. Opgericht in 1988, hebben we ons ontwikkeld tot een professionele fabrikant van plastic mallen, plastic producten, oppervlaktebehandeling, assemblage en andere gerelateerde diensten. We hebben een reputatie opgebouwd voor kwaliteit en klantenservice in de markt.

Belangrijkste kenmerken:

  • Kwaliteitsgarantie: Wellmei streeft ernaar kwaliteitsproducten en -diensten te leveren door middel van kwaliteitsborging en kwaliteitsverbetering in de productie.
  • Transparante werkwijze: Wij streven naar transparantie en geven informatie vrij over de herkomst van grondstoffen, producttesten en concurrerende prijzen om het vertrouwen van de klant te winnen.
  • Diverse producten en diensten: Onze producten omvatten een breed scala aan plastic producten zoals auto-onderdelen, medische apparaten, huishoudelijke apparaten, OA-apparaten, mobiele communicatieterminals, enzovoort. We bieden ook plastic mallenproductie, oppervlaktebehandeling, assemblage en andere diensten.

Producten en diensten:

  • Productie van kunststofmatrijzen: gespecialiseerd in verschillende soorten matrijzen, zoals E-mold, 2Kmold en IML-matrijzen.
  • Spuitgieten van kunststofproducten: spuitgieten voor de automobiel-, medische, consumentenelektronica- en andere industrieën.
  • Oppervlaktebedrukking en -coating: Oppervlaktebehandelingen: Esthetische en functionele verbeteringen aan producten.
  • Assemblage: Wij bieden complete assemblagediensten voor eindproducten of halffabricaten.

DongGuan Wellmei Industrial Co., Ltd. behoort tot de top 10 fabrikanten van spuitgietmatrijzen in China en levert de beste oplossingen, kwaliteit en diensten in de kunststofspuitgietindustrie.

6. Richfields-corporatie

China mal bedrijf

Jaar van oprichting: 2001

Locatie: Dongguan-stad, provincie Guangdong.

Industrie: Spuitgieten productie

Prijzen en certificeringen: ISO/TS 16949/2009, GMP-gecertificeerd.

Richfields Corporation is een bekend Chinees bedrijf dat mallen produceert van de beste kwaliteit en tegen een betaalbare prijs. Ze maken gebruik van geavanceerde technologie en met meer dan 30 jaar ervaring zijn ze onvergelijkbaar in hun professionaliteit en inventiviteit. De strategische positie en klantgerichte aanpak van deze merken zijn de belangrijkste redenen waarom ze door de meeste toonaangevende bedrijven over de hele wereld worden geselecteerd.

Richfields exporteert naar landen zoals Frankrijk, Duitsland, de VS, het VK, Brazilië en andere. Ze beperken zich niet alleen tot het maken van kunststof spuitgietmatrijzen, ze bieden ook een scala aan aanvullende diensten aan, zoals hot runner- en cold runner-matrijzen, over-matrijzen en rubbermatrijzen, assemblage, enzovoort. Hun expertise strekt zich uit van precisie-kunststof spuitgieten tot gas-assist spuitgieten en de productie van grote veiligheidsproducten zoals haken, randafdekkingen, deurstoppers, banden en snoeropwinders.

 

7. Huizhou Dj-gieten

China mal bedrijf

Jaar van oprichting: 2010

Locatie: In de stad Huizhou, provincie Guangdong, China.

Industrie: Spuitgietfabrikant

Prijzen en certificeringen: ISO 9001:2008-normen

Huizhou Djmolding Co.Ltd is een van de meest professionele fabrikanten van plastic mallen in China, wat de hoofdactiviteit van ons bedrijf is. Ze staan bekend om het leveren van de beste mallen in hun klasse met behulp van geavanceerde, geavanceerde machines en technologieën die de hoge betrouwbaarheid van de klant garanderen.

Aangeboden diensten en producten:

  • Rapid prototyping-diensten en prototype-spuitgieten zijn de meest kosteneffectieve methoden om het ontwerp te finaliseren en gereed te maken voor massaproductie.
  • Automobiel spuitgieten
  • CNC-bewerkings- en freesdiensten, die zeer nauwkeurig zijn.
  • oud en matrijzenbouw.
  • Productie van kunststof spuitgieten
  • Spuitgietgereedschappen en spuitblaasvormen met behulp van geavanceerde technologieën.
  • Mallen voor huishoudelijke apparaten
  • Het ontwerpen en vervaardigen van spuitgietmatrijzen behoort tot de belangrijkste diensten die ons bedrijf aanbiedt.
  • Op maat gemaakt kunststof spuitgieten.

8. SINO-SCHIMMELS

spuitgietmatrijs china

Jaar van oprichting: 1999

Locatie: De Huangyan Taizhou, provincie Zhejiang, China.

Industrie: Productieproces voor kunststof spuitgietmatrijzen

SINO MOULD is een fabrikant van kunststof spuitgietmatrijzen in China met een wereldwijde reputatie en levert producten aan landen als het VK, de VS, Frankrijk en Spanje. Ze beweren dat ze de 100% klanttevredenheid garanderen door garantie en garantiediensten te bieden, en ook door kwaliteitsmatrijzen te leveren tegen lage prijzen en binnen een korte periode.

Aangeboden diensten en producten:

  • Mallen voor huishoudelijk gebruik en huishoudelijke apparaten.
  • De mallen en vormen van de verpakking vereisen een hoge precisie.
  • Industriële mallen zoals bijvoorbeeld koelkastmallen en druppelaars.
  • De matrijzen voor de buisfittingconnector en de dunwandige container moeten worden bewerkt.
  • Medische industrie en mallen voor componenten en verfmallen.
  • De vervaardiging van automallen, kratmallen en kunststof spuitgietmatrijzen voor airconditioning.

9. Sakura-technologie

spuitgietmatrijs china

Jaar van oprichting: 1995

Locatie: Sjanghai

Bedrijfstype: Productie

Belangrijkste producten: Spuitgietmatrijzen

Sakura Tech, opgericht in 1995, is uitgegroeid tot een topproducent van kunststof mallen. Hun specialiteit omvat processen zoals overmolding, rotatiegieten en compact molding, en nog veel meer. Ze zijn populair vanwege het leveren van hoogwaardige en duurzame interieurs aan exterieuronderdelen van auto's en vliegtuigen. Het bedrijf wordt geleid door een team van getalenteerde ontwerpers en ingenieurs die bekend staan om hun legendarische producten.

10. TK Groep(Holdings) Limited

spuitgietmatrijs china

Jaar van oprichting: 1983

Locatie: Shenzhen, Suzhou, Huizhou, Vietnam en Duitsland

Bedrijfstype: Productie

Belangrijkste producten: Spuitgietmatrijzen

TK werd in 1983 opgericht in Hong Kong. Na 40 jaar ontwikkeling is TK Group nu een bekende onderneming in kunststofinjectie en het maken van mallen. TK werd in 2013 succesvol genoteerd op het hoofdbord van de Hong Kong Stock Exchange, aandelencode: 02283. Een onafhankelijk marktonderzoeksbureau IPSOS meldde dat de omzet van TK's kunststofmallenbedrijf op nummer 1 stond in de MT3-niveau leveranciers in China.

TK is een toonaangevende kunststof mal en spuitgietbedrijf in China, dat industrieën bedient zoals consumentenapparatuur, automobiel, elektronica en andere. De adoptie van de nieuwste productietechnologie in automatiseringsprocessen heeft enorm bijgedragen aan hun blijvende succes in het licht van de groeiende concurrentie van nieuwkomers op de markt.

Eindnoten

Het Chinese industriële landschap is druk en het is gemakkelijk om te verdwalen in de vele industrieën om de beste te vinden die past bij uw beoogde vereisten. Om de zoektocht gemakkelijker te maken, hebben we de nodige informatie verzameld over spuitgietfabrikanten in China en de top bedrijven die mallen produceren in de omgeving.

Plasticmol.net is de juiste keuze en dient als een one-stop-oplossing om aan al uw behoeften op het gebied van mallen te voldoen, omdat we hoogwaardige producten tegen concurrerende prijzen leveren. We hebben een transparant prijsbeleid. Ontdek ons brede assortiment producten en diensten van bredere prospects, die gemakkelijk op dezelfde plaats beschikbaar zijn.

Gereedschap voor kunststof spuitgieten

The first step in gietvorm designing for injection molding is to obtain the necessary data. This entails figuring out how many cavities there will be, choosing the material for the mold, and gathering relevant information. This may necessitate working with specialists like material engineers and tool makers,  cost analysts. Even though the molding material is usually not chosen by the mold designer, successful mold design requires a grasp of several important factors. Check the plastic part ribs design tips.

Material Choice for Mold Design

Understanding the properties of the molding materials is essential when designing injection molds. varying materials and even grades have different shrinkage rate, so it is import to confirm this first thing before start mold design, because if the shrinkage have set in the mold design, later on you can not change to other shrinkage material, because that will change to the part dimensions. Some plastics are better at absorbing and dissipating heat, which affects how well the mold cools down. This may affect where the mold’s cooling channels are located, and gate, runner, and vent designs are greatly influenced by the plastic’s viscosity.

Considerations for Shrinkage

A key consideration in mold design is shrinkage rate, or the contraction phase that occurs in polymers. The amount that a part will shrink after being taken out of the mold is determined by the shrinkage factor that is allocated to each type of plastic. Plastics can shrink in an anisotropic or isotropic manner. Similar to amorphous materials, isotropic materials shrink uniformly in all directions. On the other hand, anisotropic materials—which are frequently crystalline—may exhibit greater shrinkage along the flow direction.

For example, to attain the necessary size after shrinkage, a 6-inch product with a shrink factor of 0.010 in./in. needs a mold cavity of 6.060 inches. The three categories of shrink factors are as follows: low, which falls between 0.000 in./in. and 0.005 in./in., medium, which falls between 0.006 in./in. and 0.010 in./in., and high, which falls beyond 0.010 in./in.

Shrinkage rate

Applying shrink factors to each inch of the product has an effect on all of its dimensions. Three categories of shrinkage—low, medium, and high—have an impact on the dimensions of the mold cavity. Shrinkage may be impacted by mold temperature fluctuations as well as modifications to the product’s wall thickness. It’s difficult to estimate shrinkage; material suppliers, moldmakers, and seasoned molders must all weigh in. if you are not know what shrinkage should you use, no need to worry, only need to tell us about the material you prefer to use for your project, and we will handle the rest for you.

Below table is shrink rate for most popular materials

Full name of Materiaal Short name of material Min to Max Shrink Values
Acrylonitril Butadieen Styreen ABS .004 – .008
Acrylonitrile-Butadiene Styrene/Polycarbonate PC/ABS .004 – .007
Acetaal POM .020 – .035
Acryl PMMA .002 – .010
Ethylene Vinyl Acetate ( EVA .010 – .030
High Density Polyethylene HDPE .015 – .030
Low Density Polyethylene LDPE .015 – .035
Polyamide – Nylon (PA) Filled 30% Glass Fiber PA+30GF .005 – .007
Polyamide Nylon (PA) Niet ingevuld PA .007 – .025
Polybutylene Terephthalate PBT .008 – .010
Polycarbonate PC .005 – .007
Acrylonitrile Styrene Acrylate ASA .004 -. 007
Polyester .006 – .022
Polyetheretherketone KIJKJE .010 – .020
Polyetherimide PEI .005 – .007
Polyethyleen PE .015 – .035
Polyethersulfone PES .002 – .007
Polyphenylene PPO .005 – .007
Polyphenylene Sulfide PPS .002 – .005
Polyphthalamide PPA .005 – .007
Polypropyleen PP .010 – .030
Polystyreen Postscriptum .002 – .008
Polysulphone PSU .006 – .008
Polyurethane PUR .010 – .020
Polyvinyl Chloride PVS .002 – .030
Thermoplastic Elastomer TPE .005 – .020

Determining Cavities in Mold Design for Injection molding

Finding out how many cavities are required is an important first step before discussing mold size and equipment requirements. This parameter is crucial in determining how much can be produced by the injection molding process in a specific amount of time, together with the overall cycle time.

The yearly production volume targets for a certain product are directly related to the number of cavities needed. For example, the computation requires knowing the annual production time available if the goal is to create 100,000 units on average annually. This is 6,240 hours a year (52 weeks * 5 days/week * 24 hours/day), assuming a typical workweek of five days and 24 hours per day. Then, every month has an average of 520 available hours (6,240 / 12).

Estimating Cycle Time

Estimating the cycle time is essential to figuring out how many cavities are needed. The thickest wall portion of the item being molded has the biggest impact on the cycle time. A guideline for this estimation is shown in Figure 2-3, which takes into account the assumptions of an appropriately sized molding machine and typical injection process times. Although cycle times may vary significantly depending on the material, the chart provides a useful starting point.

Once the total cycle time has been approximated, the number of cycles per hour can be computed by dividing the estimated cycle time by 3,600, which is the number of seconds in an hour. For instance, 100 molding cycles are produced per item if the maximum wall thickness is 0.100 inches and the cycle time is roughly 36 seconds.

Cavities and Production Scale

Suppose we have an annual requirement of 100,000 units. To satisfy this criterion, a single-cavity mold would require about 1,000 hours, or 8.33 weeks. As an alternative, the production time might be cut in half to 4.16 weeks with a two-cavity mold. A two-cavity mold’s financial ramifications, however, must be carefully considered.

A single-cavity mold operating nonstop would not be feasible for larger manufacturing numbers, such 10 million units annually. In this instance, 624,000 units might be produced annually using a 16-cavity mold. Multiple molds with 16–32 cavities each might be considered, with production spaced out over three to six months, in order to reach 10 million pieces. However, it’s important to assess aspects like cost and the availability of molding equipment.

Selecting the Right Material for Injection Mold Design

Choosing the appropriate material for injection mold design is a critical aspect that significantly influences the efficiency and effectiveness of the molding process. Various materials, ranging from steels to alloys and even aluminum, offer unique characteristics catering to different molding requirements.

Steels

  1. 1020 Carbon Steel: Ideal for ejector plates and retainer plates due to its machinability. Carburization is required for hardening.
  2. 1030 Carbon Steel: Used for mold bases, ejector housings, and clamp plates. Can be easily machined and welded, with the potential for hardening to HRC 20-30.
  3. 4130 Alloy Steel: High-strength steel suitable for cavity and core retainer plates, support plates, and clamping plates. Supplied at 26 to 35 HRC.
  4. S-7 Tool Steel: Shock-resistant with good wear resistance, used for interlocks and latches. Hardened to 55-58 HRC.
  5. P-20 Tool Steel: Modified 4130, pre-hardened for cavities, cores, and stripper plates. Supplied at HRC 28-40.
  6. S136 stainless steel: This is one of the best harden material for cavities, cores, inserts an other forming mold components, hardened to 50-54 HRC.
  7. NAK80 high polishing steel: Used for high glass surface finished cavities, cores and other mold inserts, pre-hardened to 38-42HRC.
  8. 1.2344 and 1.2343 steel? This is harden steel that mostly used for cavities, cores, and other mold components, hardened to 50-54 HRC.

Aluminium

The most common aluminum grade for molds is 7075 (T6). This aircraft-grade alloy, when anodized, achieves a surface hardness of up to 65 Rc for enhanced wear resistance. It can be used for the entire mold, and its surface tends to self-smooth, reducing mold build and injection molding cycle times.

Beryllium-Copper Alloys

These alloys, such as CuBe 10, CuBe 20, and CuBe 275, are often used as components fitted to steel or aluminum mold bases. They assist in heat dissipation, particularly in areas with challenging cooling channel placements. The hardness ranges from Rb 40 to Rc 46.

Other Materials

While less common, other materials like epoxy, aluminum/epoxy alloys, silicone rubbers, and wood can be used for molds, primarily for small-volume or prototype production (typically under 100 pieces). These materials are not suited for high-volume production due to their limited durability and may be more appropriate for prototyping purposes.

In recent times, aluminum, especially the 7075 alloy, has become a viable option even for high-volume production, challenging the traditional perception of aluminum being suitable only for low-volume or prototype molds. The choice of mold material should align with production volume requirements, material compatibility, and the specific characteristics needed for the molding process.

Surface Finish and Special Requirements in Mold Design for injection molding

When it comes to molded product design, getting the right surface look is important, both aesthetically and in terms of making finishing touches like brand logos or ornamental artwork easier to apply. The parameters of the injection process and the state of the mold cavity have a direct impact on the molded surface quality. Mold designers cannot control processing parameters, but they must specify criteria for specific appearances in order to fabricate molds with the right surface conditions.

Different machining techniques produce different degrees of surface roughness on mold surfaces, which affects the finishing procedure. For example, common finishes produced by Electrical Discharge Machining (EDM) range from 10 to 100 microinches (250 to 2,500 micrometers). It may only take less than 1 microinch (25 micrometers) to get a mirror finish.w hile an average reading for most parts might fall between 20 to 40 microinches (500 to 1,000 micrometers).

A smoother cavity finish reduces the hills and valleys that are produced during machining, which usually makes it easier to eject molded pieces. The effect of EDM on cavity surface roughness is shown in Figure 2-4, which highlights the necessity of appropriate stoning and polishing in order to provide the required smoothness. For mold cavity surface finishes, the Society of the Plastics Industry (SPI) has created standards. There are three levels (1, 2, and 3) in each grade (A, B, C, and D), with A-1 being the smoothest finish and D-3 being a coarse, dry-blasted finish.

Although a flat surface facilitates ejection, too smooth surfaces might generate a vacuum, especially when using stiff, hard resins. In these situations, a small amount of surface roughening on the metal aids in removing the vacuum and enables appropriate part ejection.

If post-molding finishes are applied, the molded part’s surface requires preparation. For polyolefins, oxidation of the surface is necessary to facilitate the adhesion of paint, dye, hot-stamps, or other decorative finishes. Minimizing the use of mold release agents during spuitgieten is advisable to avoid interference with adhesion, further emphasizing the importance of a highly polished mold surface.

Identifying surfaces designated for post-molding decoration on product drawings is essential. This notification ensures that moldmakers and molders recognize critical areas requiring special attention in the finishing process.

Gate Method and Location

The final quality, appearance, and physical attributes of a molded product are influenced by the gate’s location and the type of gating system employed. Ideally, the cavity should be gated so that the molten material enters the thickest section of the part first, as illustrated in below picture.Gate location

This concept is grounded in the behavior of molten plastic molecules, which tend to occupy available space and seek equal air distribution. Placing the gate in the thickest part of the cavity forces the molecules together, compressing them as they travel into the cavity. This compaction expels air between the molecules, resulting in a densely packed molecular structure and a molded part with optimal structural integrity.

Contrarily, gating at the thin end allows the molecules to expand, increasing the air spaces between them and leading to a weaker molecular bond. This results in a molded part with low structural integrity.

While the ideal gate location and design will be explored in a subsequent chapter, it is crucial to recognize potential gate locations at this stage. Identifying these locations enables proactive communication with the product designer to address any issues. Gates, regardless of type, will leave evidence, known as a vestige, either protruding from or broken into the molded part. It will never be perfectly flush with the molded part. If the vestige hinders the function, appearance, or intended use of the molded part, the gate may need relocation, a decision in which the product designer should be actively involved.

Ejector Method and Location

After the molten plastic has solidified within the mold, the final molded product needs to be ejected from the mold. The predominant method for this task involves the use of ejector pins, which are employed to push the molded part out of the cavity where it took shape, as depicted in below picture.Ejector location

To optimize the ejection process and minimize stress, it is advisable to use ejector pins with a larger diameter. This ensures an even distribution of ejection force across the molded part, reducing the risk of cracks or punctures caused by insufficient ejector area. Ideally, ejector pins should be strategically positioned to apply force to the strongest areas of the part, such as near corners, under bosses, and close to rib intersections. Although round ejector pins are the most common and cost-effective, rectangular cross-sections are also viable.

Similar to gates, ejector pins leave traces on the molded part. Due to the continual expansion and contraction of various mold components during the molding process, achieving perfect flushness with the part’s surface is challenging. Consequently, if the pins are too short, they leave a protrusion or excess plastic pad, known as a witness mark, as illustrated in below picture. Conversely, if the pins are too long, they create impressions in the plastic part.

matrijsontwerp voor spuitgieten

It is crucial to strike a balance in pin length. Excessively long pins can lead to the molded part remaining on the ejector pins, posing the risk of damage if the mold closes on the non-ejected part. Consequently, it is prudent to intentionally keep the pins short, resulting in a thin pad of excess material. Product designers must be informed of the intended locations of ejector pins and the resulting witness marks to make informed decisions regarding acceptance.

If the witness marks are deemed unacceptable due to functional or aesthetic considerations, alternative ejection methods, such as a stripper plate or an advanced air blast system, may need to be explored. Alternatively, repositioning the part in the mold to allow for the relocation of ejector pins is another option, albeit one that may incur higher mold costs.

Location of Cavities and Cooling Channels

When employing a single-cavity mold, it is optimal to position the cavity at the center of the mold. This configuration facilitates sprue gating, creating favorable conditions for the molding process. Material injection occurs directly into the cavity, minimizing travel distance. With no constraints, injection pressure can be reduced, and stress is effectively minimized. These conditions are sought even in multicavity molds.

In the case of multicavity molds, it is essential to place the cavities as close to the center of the mold as possible. However, considerations must be given to the need for ejector pins for both the parts and the runners responsible for transporting material to the cavities. Additionally, cooling channels must be strategically placed in the mold plates to bring coolant, typically water, as close to the mold cavities as possible without compromising the integrity of the steel and causing water leaks.

It is important to carefully position the cavities to avoid interference with mounting bolts and ejector pins. As the number of cavities increases, the layout becomes more intricate, making the process more challenging. A general guideline is that cooling channels should be situated no closer than twice their diameter from any other object, as depicted in below picture. This ensures there is enough surrounding metal to minimize the risk of breakthrough.

Cooling channels for injection molding

An ideal layout for a multicavity mold resembles spokes in a wheel. This layout allows the cavities to be positioned as close as possible to the center of the mold and eliminates right-angle turns in the runner system. Such turns result in a 20% pressure drop for each turn, necessitating an increase in the runner diameter to maintain proper material flow. This escalation leads to higher material costs and longer cycle times and should be avoided whenever feasible. below picture illustrates a typical spoke layout for an eight-cavity mold.

8 cavity mold design

Despite the advantages of the spoke concept, it comes with a limitation on the total number of cavities possible within a given mold size. A squared pattern, as shown in Figure 10, can accommodate more cavities. However, squared patterns introduce turns in the runner system, often represented as right angles. Right-angle turns demand additional injection pressure to propel material through, prompting a 20% increase in the primary runner diameter to balance pressures. If squared patterns are necessary, it is preferable to have runners with sweeping turns instead of right angles,

square layout for mold design

Figure 10

Regardless of the runner system employed, ejector pins are essential for ejecting both the runner system and the molded part. Therefore, the cavity layout must consider not only the proximity of cavities to the mold’s center for minimal material travel but also how to avoid placing ejector pins (and mounting bolts) in the middle of cooling channels.

Above items are only a general requirements regarding mold design for injection molding, there will be some more requirement, such as Venting Concepts, Dimensioning of Mold, mold slider or lifter, and so on, to design a mold is not easy skill. if you want to have mold design for injection molding, you can contact us for a quote.

Injection Mold Design Case Study from Sincere Tech – DFM Anylisis

In order to be able to think in the same way within SinereTech, and to be able to use dimensions that are suitable for all applications we have created the following guidelines. Those mold design guidelines will be used by the calculation engineers as well as a base for our designers in case of any Injection mold project, and sometimes we may call this as DFM-rapport anylisis as well.

  1. Injection gate and overall layout.

    1. Generally, the injection gate will be placed along the longest side of the part and the injection gate cylinder will be on the closest distance to that side (runner will normally not go around the cavity like a banana).
    2. If sliders are used or if other factors may influence the placement of the injection gate or runner, provides some gate location suggestion and ask the customer which gate location they prefer. Agree with a solution before the mold design. Then the general layout will be suitable for almost all mold.Die Casting Mold Design
  2. Distance between the cavity edges and the insert edges.

    1. For normal cases, except for injection molds with bigger sliders or “deep” parts, use the distance 50-80mm. The upper limit is used for “bigger” parts and the lower limit is for smaller parts.
    2. For kunststof spuitgietgereedschap with bigger sliders the distance can be up to 90-100mm, especially when it concerns the two sides to right and left from the slider side.
    3. For really deep parts the distance may be bigger than 100mm, but then we should ask the customer for advice if suitable the customers injection molding machine.
    4. For really small parts the minimum distance of 50mm is used.
    5. The distance for the side towards the injection cylinder is the same as for the other sides, but about 10-15mm on top of that.
    6. In case we would like to optimize this distances. This can preferably be used for this type of die casting tools
  3. Distance between cavities.

    1. Generally, between each cavity, a distance of 30-50mm is used for most cases.
    2. For really small parts the distance of a minimum 15-30mm is used.
    3. For really deep parts the distance is generally bigger than 50mm, but then we should ask the customer for advice if the injection mold size is fitting to the customer’s machine.
    4. For cases when the runner is between the cavities the distance will be min 30-40mm between each cavity, use use banana gate then the desitance between each cavity will be extra 10mm more.
  4. Distance between the edge of the insert and the edge of the mold base.

    1. Generally (for normal cases) the rule is to use the same distance as what is used for spuitgieten (as long as the part do not require big sliders). That includes bigger parts, deeper parts and parts requiring smaller sliders. That means a distance of 60-90mm is OK for most molds.
    2. For molds with big hydraulic sliders, there is a need to increase the distance with 50-200mm on top of the normal distance (more than what would have been needed for injection moulding). However, for those cases, we should ask the customer for approval. One question is also how asymmetrical the mold can be in case a big slider is only used on the right or left side of the mould.
  5. The thickness of A/B plates and inserts.

    1. The thickness for both the inserts and A/B plates are mainly controlled by the part projected area. As a rule of thumb thicknesses specified in below table will be used when designing die casting molds. The projected areas are specified in cm2. For big projected areas or deep moulds it is recommended to ask the customer for approval. There may be formulas to use in case those dimensions will be optimized

Projected area (cm2) The thickness between the insert edge and backside of A/B plate The thickness between the cavity edge and backside of the insert edge
A-plate B-plate Insert-A Insert-B
1-100 35-40 40-45 35-40 38-40
100-300 40-60 45-70 40-45 40-45
300-600 60-80 70-100 45-50 45-55
600-1000 80-110 100-130 50-60 55-65
1000-1500 110-140 130-160 60-65 65-70
>1500 ≥140 ≥160 ≥65 ≥70

Finally if you are not sure what is best mold design solutions for your injection mold, you are welcome to contact us, we will offer you mal ontwerp, mold production and injection molding manufacturing service.