Custom Plastic Injection Molding Service In China

Product Details

Custom plastic parts service: Sample 3D scanning, Injection mould design and manufacturing, injection molding, ultrasonic melting

Material: Modified PP + Nylon

For this car water tank, what we provide to customers is OEM service. First of all, we can 3D scan the sample provided by the customer, and draw a 3D map that is almost the same size as the sample. Then our mold manufacturing department carries out mold design and manufacture according to this product’s 3D drawing. After the injection mold is completed, the injection moulding production is carried out, and finally, the injection molding product consistent with the customer’s sample is obtained.

Plastic Injection Molding Manufacturing Process

Material selection

As for the material of the product, the customer only pointed out that the material is PP, and explained that the cooling water tank is used to hold the coolant, and it needs to withstand a high temperature of 135° when the car is working. So it seems that ordinary high-temperature resistant PP material can meet the requirements. However, based on our experience and knowledge of auto parts, we discussed the working environment and performance requirements of the cooling water tank with the customer, and finally believed that the modified PP material used in the production of a Land Rover water tank for a British customer is a suitable Require.

The cooling water tank must withstand certain water pressure and air pressure during the operation of the car. Through the understanding of the industry knowledge, we and the customer agreed that the product needs to pass the 1.5 bar water pressure and 10 bar air pressure test. However, ordinary high-temperature-resistant PP cannot be satisfied. This idea was later verified. After the water tank mould was manufactured, we assisted the customer in first verifying that the air pressure test of ordinary high-temperature resistant PP products can only withstand the pressure of 4.5 bar, which is very dangerous.

The final test results of the modified PP+nylon product were fully affirmed by the customer. The formed water tank meets the performance requirements of high temperature and high-pressure resistance. Our experience in this type of product and knowledge of materials help customers avoid potential problems and save a lot of trial and error costs.

DFM analysis of plastic water tank for auto parts

Mold flow analysis is a guide for subsequent mold design and manufacturing and injection moulding production. It includes the rational analysis of product structure and wall thickness, the most suitable gating system design and verification. This verification process includes many aspects of simulation analysis, such as plastic filling time, filling pressure, filling temperature distribution, product potential bubbles or shrinkage defects, product weld lines and warpage. These analysis results will help us design the most reasonable injection mould to ensure the best quality automotive plastic parts and avoid various injection defects.

The Moldflow mold flow analysis software used by our engineering department is a very mature one in the mould industry. Our mould engineers have more than 20 years of experience and can avoid many potential mould modification costs caused by unreasonable original designs.

Design and manufacture of injection mold

Plastic injection mold design is based on mold flow analysis for 3D drawing of the mold. According to the guiding scheme of the mold flow analysis report, determine the gating system, parting scheme, row position/inclined roof design scheme, ejection system and cooling system of the injection mold. Then our experienced engineering team conducts 3D drawing and perfection of mold details.

After obtaining the 3D mould drawing, the plastic mould manufacturing process will be processed strictly according to the drawing. The injection mould manufacturing process mainly includes CNC, milling machine, precision grinder, lathe, wire cutting, precision EDM processing, etc. Finally, the most important mould assembly and adaptation work.

The quality control of each step in the automobile mould manufacturing process is very important. The most important thing is mould core adaptation and complete mould assembly. Match these mould core inserts that have passed the inspection, and then assemble them with the mould base to form a complete set of moulds. Mould components fit in place and moving parts such as ramps and slides move smoothly to keep the mold running smoothly during the injection moulding process. The red paint used in the mould fitting is the red lead commonly used in our industry. According to the state of the red lead, it is confirmed whether the fit between the mould inserts is appropriate.

Injection molding trial production

Before mass production, a process of small batch production of prototypes or samples of injection moulded products is called an injection moulding trial. It is a key part of testing the quality of plastic injection mould manufacturing. The main purpose of mould trial is to test the feasibility of mould design, injection moulding process parameters and raw materials, so as to adjust and optimize before mass production, and reduce unnecessary cost and time waste.

During the mould trial process, it is necessary to verify the mould design, including the shape, size, structure, and mould opening method of the mould, so as to ensure that the mold can be successfully injected. At the same time, the mold trial also needs to optimize the injection moulding process parameters, including the adjustment of injection moulding temperature, pressure, speed, injection molding cycle and other parameters, in order to obtain the best injection molding effect. In addition, the feasibility and quality of raw materials need to be tested to ensure that the quality of the final product meets the requirements.

Mass injection molding Production

High-volume injection molding production is an efficient, precise and repeatable method of manufacturing large quantities of plastic products, usually used to produce high-volume goods such as plastic products, home appliance casings, automotive parts, and toys. At the same time, mass injection molding production can also reduce production costs and improve production efficiency.

The cargo packaging pallet is a custom-made export-grade fumigation-free wooden pallet, and the corner protector and protective film fix the cartons on the pallet together, making it difficult to shift during transportation. After the loading is completed, the goods will be delivered to the port, and the goods will be shipped to the customer by sea.

Ultrasonic Hot-melt Process on Plastic Parts

We have experience in welding parts of various shapes and materials, even ultrasonic welding between nylon parts and nylon parts. The hot-melt welding between such high-temperature-resistant PP materials is not difficult.

Looking for A Trusted Plastic Molding Manufacturer

Sungplastic can provide customers with a one-stop service for OEM customization of plastic products. From communicating with customers, 3D scanning and drawing of samples, product design improvement, plastic prototype manufacturing, DFM analysis of plastic products, plastic mold design and manufacturing, injection molding, surface treatment, silk screen printing, and final shipment. We have been constantly improving our services to make it easier for customers from placing an order to shipping.

If you need to customize new plastic products, do you also want to make it a reality? When you send your inquiry to Sungplastic today, we are always ready to provide you with a free quotation and project review service.