We are A 18 Year’s Old Innovative Industrial Design Company And We Are The Largest Design Company In China.We provide one-stop product development services, including industrial design, mechanical design, Electronic Design(Hardware), firmware design, rapid prototyping,small batch production,DFM,Mold design and manufacturing, Validation&Certification, mass production, etc
INJECTION MOLDING MANUFACTURER & DESIGNER
China Tooling Deveiopment services
Once the shape of the plastic and metal parts is frozen we make the steel molds used to mass produce the housing and other parts. Our local engineers discuss the mold drawings with the China mold maker to assure the robustness and the aesthetic quality of the China injection molded parts.
China injection mold design engineering tends to be a lot more affordable than in the West, and a lot faster as well, with the first custom plastic parts often ready in 5 weeks.
It’s hard for one China mold maker to be good at everything, so over the years we have built up a roster of specialized China design injection factory for precision injection molds like cosmetic parts, optical lenses, gears, metal brackets and die-cast parts.
When all these custom injection molded parts come together in an complex electro-mechanical assembly a lot of tiny adjustments are needed and every iteration comes with a negotiation.
To make sure the project does not lose momentum our engineers stay at the China mold maker’s shops until the China injection mold design and manufacturing is done properly.
WHAT IS CHINA INJECTION TOOLING DESIGN AND ENGINEERING?
A mold is a hollowed-out block of steel that is injected with molten material such as plastic, which then hardens to take on the counterpart shape of the mold. An injection mold is necessary when an electronic project requires a custom plastic or metal housing.
WHAT ARE INJECTION TOOLING MADE OF?
Injection molds are made from a variety of steels. Examples of some common steels used in plastic injection molds include P20, NAK80, H13, and S7. Each vary in terms of hardness, wear resistance, compression strength, corrosion resistance, machining ease, polishability, weldability
CHINA INJECTION TOOLING DEVELOPMENT COST
China is well known for its unprecedented value for money with regards to injection mold design & manufacturing yet some businesses choose Western over China mold makers, assuming the quality of the steel improves the endurance of the injection mold result, resulting in a lower percentage of the costs.
Choosing for a higher quality steel might constitute to a lower percentage of the costs when made by western mold makers, yet this is only due to the high labor costs. In fact, plastic enclosure is the cost component on which you can realize the largest cost difference between China and the West.
From our experience it makes financial sense to invest in injection molding at quantities of 250 molds and up. And once you have invested in molds, the more you produce the more you save.
CHINA INJECTION TOOLING DESIGN & MANUFACTURING – CHALLENGES
Injection mold design and manufacturing is an art in itself. A good mold design will increase the chance of getting well-molded enclosures and parts, yet it is also essential to use the correct plastic injection molds parameters appropriate to the parts being produced and material used; otherwise the parts may come out defective. Common Defects in Injection Molds:
- Burn Marks: Burnt areas at furthest points from injection gate caused by an injection speed that is too high so the mold lacks venting
- Flash: Excess material caused by a too high injection speed/material injected, a damaged parting line or a too low clamping force.
- Flow marks: Wavy lines or patterns caused by an injection speed that is too slow
- Knit lines: Small lines on parts caused by the plastic flowing around an object; can be minimized or eliminated with a mold-flow analysis.
- Sink marks: Depressions caused by either a pressure that is too low; cooling time too short; or enclosure walls that are too thick
- Short shot: Incomplete parts caused by an injection speed or pressure that is too low
- Splay marks: Lines/Marks caused by gas or moisture flowing along the part during injection process
- Warping: Warped part caused by a cooling time that is too short or material that is too hot
WHAT TYPES OF INJECTION MOLDED ENCLOSURES CAN YOU DESIGN & MANUFACTURE IN CHINA?
PLASTIC INJECTION ENCLOSURES
Custom plastic enclosures give your electronic products the greatest freedom in shape and the lowest cost per unit.
POLYCARBONATE INJECTION MOLDING
It has excellent impact strength, clarity, and optical properties and can be molded to tight tolerances. Its disadvantages are its subjection to stress cracking and/or yellowing after long time.
ACRYLONITRILE BUTADIENE STYRENE INJECTION MOLDING
ABS plastic has good mechanical toughness, dimensional stability, chemical resistance, and ease of fabrication. Its disadvantages are its poor solvent resistance and it melts easily.
POLYPROPYLENE INJECTION MOLDING
Polypropylene is widely used and inexpensive but is difficult to mold to precision. Its disadvantage is its degradation caused by UV
METAL INJECTION MOLDING
Plastic Injection Molding is often the most cost effective option for production in large quantities, but for China low run injection molding, metal enclosures become affordable and will give your device a high-end quality look and feel.
A custom metal enclosure made in China can become cost effective at quantities as low as 200 pieces.
Our partners can develop fast turn-around milled (CNC) metal enclosures at reasonable prices. Once you get to quantities of 500 units, you can significantly lower the unit cost by going for a stamped metal housing produced using a progressive die. Alternatively, to get more freedom of form you could go for die-cast housings in zinc or magnesium.
All molds are carefully designed to maximize its service life and to ease maintenance, all molds are made economically and functionality to meet customer's expectations. Our design engineering operation system include:1. Pro/Engineer （Used For Mold Design In General) / UG (Used for Product Development 3D Modeling) / SolidWork 2. AutoCad (2D layout) 3. Moldflow analysis (Plastic flow/deform simulation)) 4. Rhinoceros
1. Shuttle and Insert Molds2. Multiple Slide Action Molds 3. Stripper and Floating Cavity Plate Molds 4. Hot Runner System 5. Unscrewing Molds 6. Die-casting. 7. Blow Molding 8. IML / IMF / IMD 9. Spray Painting 10. Assembly & Packaging 11. Electroplating 12. Automation for Molding
1. Molded Parts - LSR
2. Molded Parts - High Temperature Material
3. Molded Parts - Single Shot
4. Molded Parts - Two Shot
5. Molded Parts - Insert Molding
6. Molded Parts - IMD & IML
7. Molded Parts - Medical
7. Molded Parts - Medical
1.2344, 12343, S136, LKM2316, LKM738H, 1.2083, 1.2312, 1.1730, H13, P20, MOLDMAX-HH.
ABS, PC, PP, PA, PMMA, POM, PE etc
We Select Suitable Tonnage Of Molding Machine And Accurately Control Mold Time To Help Control Mold Cost
1. Dimension measuring - 3D Coordinate Measuring Machine, Video Measuring system (VMS), Gear Rolling Tester
2.Material test - Melt Flow Index , Moisture Tester Colorimeter , Hardness tester(Rockwell and Vickers)
3. Function & Reliability test - Hi-low temperature aging tester, High temperature tester, Salt Spray Tester, Abrasion Tester, UV aging tester, Push-pull force meter/Torque meter, Simulant packaging transportation device, Drop test machine.
3. MFR Tester
4. Gear Rolling Tester
5. Spectral Colorimeter
6. Constant Temperature and Humidity Chamber
7. Moisture Tester
8. 3D Microscope
9. Salt Spray Tester
There are two main factors affecting mold qualityFirst, Mold Design Experience. LKKER SCM mold design & engineers have min.15 years mold factory experience. They are familiar with various advanced and precise mold machine, mold design operation system, and capable of supervise mold manufacturing process and cost control. Second, Precise Mold Machine. LKKER SCM mold factories has long list of advanced mold equipments at different tonnage that are capable to fulfill various mold quality standard and take good control of tolerance.
SGS, UKAS, TÜV Rheinland, UL, etc
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LKKER SCM will review the product design, then set mold quality standards and time of mold making production timeline; track and inspect mold making; review sample; prepare materials for mold modification; track mold modification and engineer assistance; make sample before the final production and keep statistics records of issues during making until the completion of the approval sample.
Transparent Document Control: DFM; mold structure 2D; mold structure 3D; product full-inspection dimension report; mold making progress sheet; mold modification report; final mold BOM; sealed sample, mold material certificate, mold verification report, and heat treatment report
Tooling Development Process
Based on the sample or related drawings provided by customers, mold design engineers conduct evaluation and analysis and prepare for formal mold drawing design. A、review of product 3D drawings A、 specific 2D assembly drawing A、release of drawings A、material and machine preparation A、 product dimensions and assembly test A、small-batch trial production
Based on the sample or related drawings provided by customers, mold design engineers conduct evaluation and analysis and prepare for formal mold drawing design.
A、review of product 3D drawingsB、preliminary 2D ranking C、 preliminary 3D parting and determination of parting lines, glue injection mode, and ejector marD. preliminary view ew of the mold structure E、make a DFM report F、 make a mold progress sheet
A、 specific 2D assembly drawingB、3D assembly drawing C、drawings of parts and loose items. D、mold BOM sheet and purchase order
A、release of drawingsB、 CNC mold core C、copper electrode making D、 mold and accessory processing E、mold assembly
A、material and machine preparationB、making samples with machine C、 mold testing report
A、 product dimensions and assembly testB、product improvement report C、 functional test and improvement report
A、small-batch trial productionB、mold quality testing and confirmation C、product dimensions and exterior confirmation D、sorting project-closing documents
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