Insert Injection Molding

Surface Finishing of Insert Injection Molding Parts– Polish / Texture

Surface Finishing is a critical step in the manufacturing process of electronics housing and directly affects the appearance and functionality of the product. Common surface treatments include polishing and texture Polishing is the process of smoothing and leveling the surface of plastics by mechanical, chemical, or electrochemical means, thereby improving their gloss and aesthetics. Texturing is done by forming regular or irregular patterns and textures on the plastic surface to achieve aesthetic and functional purposes.

Parting Line Design of Insert Injection Molding Parts

When we design the electronics housing parting line, we will consider the opening and closing direction of the mold and the way of demolding, in order to ensure the aesthetics of the product, the parting line will be designed in an inconspicuous place or the edge area of the product as much as possible, 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.

Draft Angle Analysis of Insert Injection Molding Parts

Picture 1

Before texturing, we carefully check the type of texture selected to verify that the electronics housing draft angle is appropriate for texture demolding. Different types of textures may have different requirements for the draft angle. If the draft angle is not applicable, it may result in difficulty in demolding the product or damage to the surface of the electronics housing.

Picture 2

For the green surfaces marked, the extraction angle is currently set at 0 degrees. To improve the demolding, we propose to increase 1-degree draft at the core side. This is achieved by cutting plastic. And will ensure smooth demolding of the product when the mold is opened, reduce damage to the surface of the product, and improve productivity and product quality.

Sub-Insert Design of Insert Injection Molding Parts

Sub-Insert design plays a vital role in plastic mold design, especially in the manufacture of insert injection molding products that require high precision and complex geometries. Inserts are part of the mold and can be separate components used to form specific product details or features. Picture1 is blue lines are parting lines of cavity sub insert. Picture 2 is blue lines are parting lines of core sub insert. 

Ejector Design of Insert Injection Molding Parts

When designing and arranging the mold ejector system, we considered using a variety of ejector pins to ensure the smooth demolding of the plastic products. Specifically, we used the following ejector pin sizes: Ø4 ejector pin *2, Ø4 ejector pin *2, and Ø10 ejector pin*2. In addition, we used 29.5 flat ejector pin *22 and 1.57.5 flat ejector pin*2. The combination and distribution of these ejector pins helps to ensure that the product is subjected to an even force during demolding, reducing the risk of deformation and damage, thus improving productivity and product quality.

Gate Type & Location & Size of Insert Injection Molding Parts

In the plastic injection molding process, gate type, location and size are key factors in determining the quality and productivity of the molded product. The gate location in the insert injection molding part’s center.

Reasonable design of mold layout 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 electronics housing, 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.