Custom Front Panel

Surface Finishing – Polish / Texture

The pink surface is textured. Texturing is done by forming regular or irregular patterns and textures on the plastic surface to achieve aesthetic and functional purposes. Mark 2 is line polishing which is the meticulous grinding and polishing of the mold surface using polishing tools and abrasive materials. Its main purpose is to remove minor imperfections and machining marks on the mold surface, reduce surface roughness, and improve the smoothness of the mold surface. 

Parting Line Design of Unscrewing Molds Parts

When designing the electrical bracket parting line, our mold designers will consider the opening and mold closing direction and mold demolding way, to ensure the aesthetics of the electrical bracket, the parting line will be designed in an inconspicuous place or the edge area of the product, to avoid the parting line appearing in the front of the product or important visual area, so as not to affect the overall aesthetics of the product. The red lines are parting lines, and blue lines are parting lines of sliders.

Draft Angle Analysis of Unscrewing Molds Parts

The draft angle design is critical to ensure smooth demolding. The draft angle is the angle between the mold surface and the vertical direction of the custom front panel. Correct design of the draft angle can prevent excessive friction between the finished product and the mold surface during the demolding process, avoiding scratches, deformation, or damage to the custom front panel product surface. In picture 1 the draft angles of mark 1 and mark 2 are okay, and the draft angle of mark 3 around the part can be confirmed by texture type.

In picture 2 the draft angle of mark 1 in the slider is okay， and during the mold design and manufacturing process, we discovered that there was a problem with the draft angle of the slider portion of mark 2. Specifically, the slider’s draft angle was reversed, meaning that the draft angle in the slider didn’t meet normal design requirements. This situation can lead to difficulties during the demolding process and may even cause damage to the mold and custom front panel surface. To solve this problem, we need to re-adjust the slider design so that its mold draft angle meets the standard requirements to ensure smooth production and high-quality of the custom front panel.

Slider and Lifter Design

Slider layout is a key link in mold design, which directly affects the molding quality and production efficiency. Slider layout involves the design of the shape, size, position and movement direction of the slider. A reasonable slider layout should ensure that the slider in the mold opening and closing process can move smoothly, and will not interfere with other mold components. At the same time, the slider layout also needs to take into account the cooling system and venting system of the mold to ensure uniform cooling of the product and the smooth discharge of gas. An optimized slide layout not only improves the mold service life, but also enhances productivity and product quality.

Ejector Design of Unscrewing Molds Parts

In the custom front panel design,  The ejector system is responsible for ejecting the molded part from the mold safely and efficiently, ensuring that the product is not damaged and maintaining high accuracy. In the ejector design, we consider the shape, size, material, and demolding difficulty of the electronic housing product to select the appropriate ejector method and ejector device. In the custom front panel, we use the ejector pin of Ø6 and Ø8 to eject the product.

Gate Type & Location & Size

In the mold design, we used YODO hot runner system and configured 1 injection nozzle.

At the same time, we made a special design for the gate location to avoid the generation of residue on the product surface. Specifically, a concave with a diameter of 5.0 mm and a depth of 0.5 mm (￠5.0×0.5 mm) was installed at the gate location. The this design purpose is to ensure that during the injection molding process, the gate residue does not protrude from the custom front panel surface, thus affecting the appearance and function of the custom front panel.

By adding a concave at the gate location, the excess material can be effectively collected and hidden, ensuring a smooth and flawless surface of the finished product and enhancing the overall quality and aesthetics of the product. In addition, this design can also simplify the subsequent processing and handling steps, reducing the complexity of human operation and improving production efficiency.

Reasonable custom front panel mold layout design is the basis for achieving high-quality injection molding. By optimizing various aspects such as cavity and core layout, gating system, ejector system, cooling system, parting surface, and venting system, the working efficiency of the mold and the quality of the product can be improved. The mold layout design needs to take into account the shape, size, material properties, and production requirements of the custom front panel, to achieve the best production results.

Before delivery, we will fully maintain and clean the molds to make sure the surface of the molds are smooth and internal impurities. Then anti-shock material and protective padding are packed and put into wooden crates and labeled with model and quantity information.