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Views: 0 Author: Danny Luo Publish Time: 2024-12-02 Origin: Site
Manufacturing Service: Custom Processing: DFM, Mold Flow, Mold design, Mold Making, Injection Molding Mold Material: S136 Part Material: ABS+PC V0 plication: Home Energy Storage Systems |  |
About the Customer
This customer is from America. Our customer’s company is speicalized in develop, manufacturing and sale energy storage products. He is a designer who is specializing in creating home energy storage systems that combine innovative technology with outstanding design. In 2022, he approached us to collaborate on a new project and needed us to customize injection molded for a new home energy storage system. The project involved four different parts, which were the battery cell holder, module trim, right trim and left trim.
Home Energy Storage System
Home Energy Storage System
About this Project
Project background: Whether people are looking to save on your electricity bill or be prepared for a power outage, the new Home Energy Storage Systems is a great option. So this customer designs a user-friendly Home Energy Storage System to suit the market. The customer is looking to establish a long-term and stable relationship with a plastic mold manufacturer, like Alpine Mold, to improve product quality and reduce production costs.
Project goal: We offer one stop home energy storage solutions for this customers including materials suggest, DFM report, mold flow, mold design, mold making, and injection molding services. We need manufacture the products meet the quality and cost requirements of customers.
1. The Challenges and Solutions of Project
Design For Manufacturing (DFM) Review
Battery Cell Holder
(1) Challenge: Because the product's bottom surfaces do not have an ejector pin, the product cannot be ejected when the mold is opened.
Solution: After discussing the issue with the customer, he agreed to 0.15-0.2mm glue reduction mold pulling.
(2) Challenge: The product has many narrow bone positions, which can cause difficulty in filling and deformation due to insufficient glue.
Solution: The customer agrees to increase the number of injection points to ensure that the product does not have insufficient glue.
(3) Challenge: Because the product has many structural bone positions, it is difficult to determine the optimal location and number of glue ports that are needed for the product to be completely filled during the molding process.
Solution: Our engineers have done mold flow analysis, identified that 16 injection points are optimal for filling.
Module Trim
(1) Challenge: Due to too many structural bone positions of the product, it is difficult to determine the position and quantity of glue ports required to ensure the product is completely filled.
Solution: Through mold flow software simulation, it is determined that 4 injection points are optimal for filling.
(2) Challenge: The product's inverted buckle requires the production of a slanted top, but currently the product structure is compact and the movement distance of the slanted top is not sufficient
Solution: Through mold flow software simulation, our engineers determined that 4 injection points are optimal for filling.
Right Trim and Left Trim
(1) Challenge: The product's bone positions are thick, which can cause uneven thickness marks on the product after molding
Solution: After discussing the issue with the customer, they have agreed to modify the mold design by changing all the bone positions to a width of 1.2mm for the thick end and 1mm for the thin end.
(2) Challenge: Because the product has many structural bone positions, it is difficult to determine the optimal location and number of glue ports that are needed for the product to be completely filled during the molding process.
Solution: Through mold flow software simulation, our engineers determined that 1 injection points are optimal for filling.
Battery Cell Holder
Module Trim
Right Trim and Left Trim
2. Mold Testing
Problem points encountered during mold testing | ||
Mold No. | Problem points encountered | How we solve |
22535: Battery cell holder | Product flash | Re-boil the mold and add support pillars; |
Short stroke of the front mold opening, the material head is not easy to take out | Lengthen the pull rod | |
ZS22536: Module Trim | Front mold pull (pull flower) | Repolish the mold |
Insufficient gas venting | Add exhaust inserts at corresponding bone positions | |
Top white | Repolish the mold | |
Burr | Re-boil the mold. | |
ZS22537: Right Trim and Left Trim | Insufficient gas venting | Add exhaust inserts at corresponding bone positions |
Burr | Re-boil the mold and add support pillars | |
Battery Cell Holder Mold
Module Trim Mold
Right Trim and Left Trim
Alpine Mold is a reputable and experienced manufacturer that specializes in the design and production of high-quality molds and plastic parts.There are several reasons why choosing Alpine Mold for manufacturing home energy storage system can be a wise decision.
1. Expertise in mold design
Alpine Mold has a team of skilled and experienced mold designers who can create customized molds that meet the specific requirements of home energy storage system. With over 30 years in mold design, we can provide you with optimal product optimization solutions and the suitable mold design. We can help you create molds that are efficient, precise, and reliable.
Home Energy Storage System Mold Design
Home Energy Storage System Mold Design
2. Advanced manufacturing facilities
Alpine Mold has state-of-the-art manufacturing facilities that are equipped with the latest technology and equipment. We have invested in the latest machinery and equipment to produce high-quality molds, including High Speed CNC, Charmilles EDM, Wire Cutting Machine, and ZEISS CMM Inspection Machines, etc. These facilities enable us to manufacture molds with high precision, efficiency, and accuracy. It can reach +/- 0.01mm precision.
High Speed CNC Machines
Charmilles EDM machines
3. Quality assurance
Alpine Mold is committed to providing high-quality products and services. We have a rigorous quality assurance process that ensures that each mold we produce meets the highest standards of quality and reliability.This commitment to quality assurance also ensures that all home energy storage system enclosures produced by Alpine Mold are of high quality and meet the expectations of their customers.
ZEISS CMM Inspection Machines
Quality Control
4. Great Customer service
Alpine Mold has a dedicated customer service professionals who are available to answer any questions or concerns that customers may have. We are committed to providing excellent customer service and ensuring that customers are satisfied with the products we made.
Cooperation results
Alpine Mold successfully completed the customer's Home Energy Storage System project, resulting in significantly improved product quality and effective control of production costs. The partnership between the customer and Alpine Mold has been successful due to Alpine Mold's technical expertise, manufacturing capabilities, and efficient delivery. Alpine Mold will continue to provide high-quality mold manufacturing and custom injection molding services to help customers achieve greater success in the market. Are you looking for a new project about injection molding? just feel free to contact us right now!
