Mobile Connector Injection Molding

Short Description:
• Suntime Mould has made several same plastic moulds for this kind of precision injection tools for mobile connector.
• This project has short lead time and high precision requirement.
• The parts need to do heat treatment after molding.
• It is multi-cavity (8 cavity) high temperature mould, the mould temperature reach to 120 degree, and plastic injection molding cycle time is 9 seconds.
• Moulds stay in Suntime for injection moulding production, over 100,000 parts were needed each day.

Difficulties for this project

The difficulties

High precision tolerance，high temperature mould，short mould making lead time and very short moulding cycle time. The material is Powder metallurgy material having short cooling time and high demand of injection machines.

What is powder metallurgy?

Powder metallurgy is a manufacturing process that utilizes pressurized compaction and sintering of metal particles to create a variety of parts and components. The process involves blending together powdered metals such as iron, aluminum, bronze, stainless steel and cobalt with lubricants and binding agents before subjecting them to high levels of pressure. The resulting mixture is then heated until the materials chemically fuse together, creating parts that are much stronger than traditional casted or machined components. Due to its versatility, powder metallurgy has become increasingly popular for the production of complex parts used in automotive, aerospace and consumer electronic applications.

What is high temperature mold?

High-temperature molding is a type of injection molding process that utilizes elevated temperatures and pressures to produce parts with high strength and durability. The process works by heating raw thermoplastic material until it is molten and then injecting it into an enclosed mold where it is held in place under pressure. Heat from the molten resin combined with pressure causes the material to form into the desired shape before cooling. This process allows for the creation of complex parts that are resistant to extreme temperatures and corrosive chemicals, making them ideal for use in industries such as automotive, aerospace, medical devices and electronics. Common Plastic Material includes: PEEK, PPSU, ULTEM® (Polyetherimide, PEI), Celazole®, Vespel®, Torlon® (Polyamide-imide) and so on.

Mold design for high temperature mold

When designing molds for high-temperature plastics it’s important to include heat transfer channels as well as use thermal pins to ensure the plastic cools evenly during the injection molding process. Additionally, selecting the right mold material is essential for creating parts that can withstand extreme temperatures without warping or cracking. In this project, we used steel of S136 with HRC 52~54, the production volume is very high, 100000pcs parts were needed each day, so we used 8 cavity mold and make many copy ones to meet the quantity request. For cooling, it is cooled by oil and the mold temperature reach to 120 degree. The cycle time is 9 seconds and we used 2 step ejection for parts release. This part will be heat treated after molding.

More Details

The injection mould tool is 8 cavity high temperature injection mould. Plastic is powder metallurgy materials and the molded parts will need heat treatment as it is the mobile connector. Injection moulding cycle time is very short, 9 seconds for one shot.

Drawings

We have made many copy tools for this customer. Our designers work very effective, for DFM, it is finished within 1 day, 2D layout within 2 days, and 3D within 3 days. The mold manufacturing lead time is 4 weeks. For mold design, when time is very urgent, we normally make 3D drawing directly after DFM, but of course, it must be based on customers’ approval.

FAQ