Description Of Smart Device Housing Injection Mold
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KRMOLD designs Smart Device Housing Injection Molds to meet the needs of the consumer electronics industry for the production of major plastic products, such as smartphones, AR glasses, smartwatch device plastic housings, etc. KRMOLD has successfully assisted customers in the consumer electronics industry to complete the design and production of a variety of different types of injection molds for smart device housings.
KRMOLD has successfully helped customers in the consumer electronics industry to complete the design and production of injection molds for different types of smart device housings, and is committed to providing customers with complete production solutions.
Advantage Of Smart Device Housing Injection Mold
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1.High Precision Injection Molding Design
Smart device housings usually have complex structures such as ultra-thin walls, curved surfaces, and micro holes, which need to be molded with high precision to achieve integrated molding. For example, the curved edges of smartwatch cases and the openings of heart rate sensors require 5-axis CNC machining and mirror EDM technology to ensure dimensional accuracy and avoid assembly deviation or signal interference.
Smart device housings often require high-gloss surface, matte texture or IMD (in-mold decoration) process, KRMOLD Smart home part injection mold needs to be designed to ensure that the surface needs to be polished to Ra ≤ 0.02 μm (mirror-grade), and through etching or laser engraving to achieve complex patterns.
2.Meet the demand for multi-material production of smart device housing
Smart Device Housing Injection Mold can process high performance plastics such as PC+ABS, glass fiber reinforced nylon and LCP, etc. Smart Device Housing requires optimized gate design to prevent fusion marks when designing the injection mold.KRMOLD has also made breakthroughs in the demand for innovative materials, such as Liquid Silicone Rubber (LSR) encapsulated plastic, bio-based plastics (PLA/PLA) and bio-based plastics (PLA/PLA/PLA), Bio-based plastics (PLA/PHA), etc. require adjustments to the temperature control and release angle of the injection mold.
3. Improve production efficiency and reduce production costs
Smart Device Housing Injection Mold usually adopts multi-cavity mold with full hot runner system, which can shorten the molding cycle time to 5 seconds/mold, and increase the production efficiency by more than 50%. At the same time, matching with robot automatic pickup, vacuum feeding system to reduce manual intervention, combined with AI mold flow analysis to optimize the parameters (such as pressure, temperature), to reduce the number of times of mold testing by more than 30%.
Common Injection Molding Processes
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In-Mold Molding (IMD) Technology
In-Mold Decoration (IMD) is a process that combines printed decorative films with injection molding. By embedding a pre-printed film into a mold, the resin is fused with the film during injection molding to achieve the integration of surface decoration and functionality. The in-mold injection molding production process usually consists of film printing and pretreatment, film positioning and mold closing, injection resin filling, film and resin bonding, and finally cooling and demolding to form a decorative surface.
IMD supports metal plating, imitation glass, three-dimensional texture and other complex effects to meet the smart phone shell can be screen printing or screen printing technology to achieve gradient color, micro-engraved logo design, etc. IMD process ink layer is covered by a transparent film, not only to maintain the color vibrancy, but also with fingerprints and anti-glare characteristics, in line with the appearance of high-end smart devices needs.
Through high-pressure molding technology, IMD can realize 3D three-dimensional modeling on a film with a thickness of 0.1-0.3mm, while maintaining the overall thickness of the shell ≤ 1.5mm, which can avoid the seams caused by bonding or snap in the traditional assembly, and improve the waterproof and dustproof performance.
Multi-cavity injection molding
Multi-cavity injection mold using S136H, NAK80 high wear-resistant steel mold material through the five-axis CNC machine + EDM molding, usually using symmetrical arrangement (such as 4-cavity, 8-cavity, 96-cavity) to balance the melt flow, the main flow channel and manifolds need to be optimized through the mold flow analysis. Achieve single-shot molding of multiple pieces, suitable for high-volume manufacturing to reduce the number of molds and mold change time, single-piece cost reduction of 20% -40%.
The output of smart device housing products requires the use of more efficient injection molds to meet market demand. Intelligent device shell injection mold using multi-cavity molding design process can help reduce the cost of a single piece of intelligent device shell products can be reduced by 30%-50%!
KRMOLD Injection Mold Manufacturing Equipment
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CNC Machine
CNC Milling Machine is used for milling, drilling, tapping, precision engraving, etc. It is suitable for machining mold cavities, cores, parting surfaces, cooling water circuits, ejector holes, etc. KRMOLD adopts the international famous CNC machining brands, such as Japan's Makino V33 to ensure the precision of mold machining.
Electrical Discharge Machine（EDM）Machine
CNC Electrical Discharge Machine (EDM, Electrical Discharge Machine) is a kind of CNC equipment using electric spark discharge for precision machining of metal materials for injection molds, which is mainly used for the manufacture of molds or precision parts with high hardness materials, deep cavities and complex shapes.
Wire Cut Machine
Wire Cut Machine is a CNC machine that cuts injection molds with high precision by using fine wires as electrodes and etching the metal through pulse discharge.KRMOLD uses ALN600Gs from Sardick Japan to ensure the precision of mold processing.
KRMOLD Service For Injection Mold
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1.One-stop full-process service
We provide full-process service from integrating requirements, mold design and manufacturing to delivery and after-sales service.
The technical team is deeply involved in the customer's product design stage, optimizing the mold structure and designing the mold drawings through the mold flow analysis software (such as Autodesk Moldflow, UGNX). Equipped with imported CNC, Shadick wire cutting machine, mirror discharge equipment and other precision processing equipment to achieve ±0.02mm precision;
We have a large-scale intelligent workshop to support secondary processing such as silk-screen printing, welding, spraying, etc. We strictly implement the quality system of ISO13485 and IATF16949; meanwhile, we provide free transportation, regular mold maintenance and one-year warranty service.
2.Complete quality control system
There is a full chain production workshop, using Makino five-axis machining centers, Haitian injection molding machines and other well-known equipment at home and abroad to avoid delays in outgoing processing. Through the CMM coordinate measuring machine, three-dimensional inspection instrument full inspection of key dimensions, the implementation of PDCA cycle quality management. Meanwhile, we provide complete quality inspection report of injection molds.
3.Accurate delivery control to guarantee the project schedule
Through digital management, production progress monitoring from the beginning of the order, for different orders and delivery date for data monitoring, once there are factors that may be delayed, immediately arrange to speed up the production schedule, to ensure that the customer in the delivery period to complete the manufacturing of plastic injection molds.
Specify the type of plastic (e.g. PP, ABS) and post-processing requirements (e.g. spraying, silk-screen printing), and provide 2D or 3D plastic part drawings should be provided. At the same time, provide the production volume, appearance requirements, tolerance standards, etc.
Generally speaking, our engineers will start to prepare the quotation immediately after the customer provides the complete production requirements. Usually it takes about 1-3 days.
The lead time for regular injection molds is usually 30-60 days, and may be longer for complex molds. For example, the typical lead time for liquid silicone molds is around 60 days, covering design, manufacturing, mold testing, etc.
High-precision processing technology: High-precision equipment such as CNC machining centers (CNC) and electric discharge machining (EDM) are used to optimize the design process in combination with CAD/CAM software. Quality control: Inspection of key dimensions of the mold by Coordinate Measuring Machine (CMM) and verification of multiple sample batches during the trial molding stage. Material Selection: Use die steel with high wear resistance (e.g. H13, S136) and surface treatment (e.g. nitriding, chrome plating) for die nuts to extend the life.
After every 50,000 molds, check the guide pillar, ejector pin and other wear parts, and clean up the residual plastic and rust on the mold surface. Use high temperature grease for sliding parts (e.g. tilt top, slider) to reduce friction loss. Ensure that the water circuit is smooth and the temperature difference is ≤5℃ to avoid cracking of the mold due to thermal stress.
Mould cost of materials accounted for about 30-40% (such as 1 ton of P20 steel price of about 20,000 yuan), processing costs accounted for more than 50% (CNC labor hourly rate of about 80-150 yuan / hour). Small batch production can choose aluminum mold or simplify the structural design; more than 100,000 pieces is recommended to use carbide inserts to enhance life!
Mould injection products need to fully meet the design requirements (such as size, appearance), and can be continuous and stable production. Mold marking, inspection reports (such as material hardness test) and engineering drawings should be complete.
Mould steel (such as S136H, NAK80 and other imported materials cost more) and the type of mold embryo (aluminum mold short-term cost is low but short life) directly affect the cost, the use of CAD/CAE/CAM design technology, hot runner system, etc. will increase the upfront investment, but can enhance the long-term benefits (such as reducing the sprues, increase production capacity).
