OEM Customized Injection Molded Plastic Parts for Ipad Holder/Ipad Bumper

Deep Mould would like to show an real example of our customized injection plastic parts,the part name is Ipad plastic holder/Ipad bumper, the material is PC-ABS and PC Clear.

Basic part information

• Part name: Ipad cover/Ipad holder/Ipad bumper

• Plastic material: BAYBLEND FR3010

• Surface Finish: VDI 3400 Ref.18

• Color: Black

• Production volume: 500K

• Core and Cavity Steel:1.2344 HRC 48-52

Considering the electrical switch holder outer surface are visible, Deep Mould used a sub gate at the plastic holder's edge position, sub gate has the minimum gate mark left over and easy to break off during the mass production,this cause the runner with the part can be seperate automatically.
 

Basic mold information

• Gate type: Sub Gate

• Cavity number: 1+1

• Shrinkage: 5/1000

• Molding Machine (Tons):Haitian 120T

• Mold type: 2-Plate

   

Before Deep Mould start the machining of the injection mold,our engineers have made DFM report and mold 3D mold design for our customers,we verified some important information with our customer, i.e. parting line, gate position, ejection, surface treaatment,thickness and so on.


The progress of injection mold making Deep Mould took 3 weeks, then Deep Mould have the first mold trial and send samples to our customers. Considering T1 sample parts might need to adjust some dimensions,so Deep Mould didn't make surface with VDI 3400 Ref.18 texture for T1 samples, part surface was just polished with SPI B2.

Deep Mould sent T1 sample parts to customer by DHL, and got approval from the customer. Customer agreed to make surface texture, then directly start mass production of the Ipad bumper/Ipad holder, during mass production, we have a welding line problem.The lines across the plastic are highly visible and unacceptable by customer, the welding line is quite slim while the part surface is polish, it gets blemish look while the part surface is matt.


The reason of the welding line is simply because melt flows are spitted by steel/insert and meet on the other side, it occurs on all holes features usually, to make it as invisible as possible, the mold temperature needs to be as high as possible, so the resin melt temperature does not drop too much while it flow over the mold inserts and meet on the other side.

We also change the gate position and a sub gate to allow faster melt flow, problem was resolved at the end, take a look how we packed the parts.


Welding lines are a typical defects for injection molded parts with many hole features, such as computer key board typically, the hot resin flow around the little inserts and melt flow meet each other on other side where the welding line occurs, this is how welding line occurs, melt flow temperature always drop while melt resin flow over the mold cavity, that is why the welding line can only be optimized but can not be completed removed if you simply use higher mold temperature, in some other cases, changing gate position would just change the welding line to a less critical location, but for a product similar like computer key board, neither mold temperature or changing gate location would work, as a consumer product, the surface finish is quite critical thing, so as you can see now most of the key board product was painted nicely to cover the welding line defects.

Basic Plastic Parts Injection Information

Finally 2 weeks after,we have solved the problem and get the mass production confirmation from our customers.

Each day we can produce over 1600 sets plastic covers for our customers. Customer is really happy with the final parts and fast speed sell their final parts to the market.

If you have the similar projects,please feel free to contact with us,Deep Mould is looking forward to support your team!

Contact Us

B Block,No 21,Nan Xing Three Street,Nan Fang Industrial Park,

Bei Ce,Humen,Dong Guan,Guang Dong,China.

info@deepmould.com

Skype: Deepmould

Tel/Wechat: 86-15024107707

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