Custom ABS & Nylon 66 Injection Molding Solutions for Rabbit Tunnel Systems

Our One Stop Services: From Mold Design to Injection Molding  Number of Molds: 6 sets Mold Material: S136H Parts Material: ABS (757) + UV, Nylon PA66 (101L) + UV Parts Color: Mid Grey, Green Surface Finish: YS20023/YS20021 Polished

About the Client and the Project

Our client is a UK-based pet product designer with a passion for creating innovative, high-quality pet accessories. Their company specializes in the design, development, and sale of various pet products, including cages, tunnels, toys, and other accessories. In 2017, they launched the Zippi Rabbit Tunnel System, a smart solution to connect rabbit hutches to outdoor enclosures, ensuring pets' safety while allowing them to explore.

The client chose Alpine Mold to produce six high-quality molds for the tunnel connectors, door frame kits, and support hoops for this rabbit tunnel system. The molds were crafted using S136H steel, and the components were made from ABS + UV and Nylon PA66 + UV to withstand outdoor use.

Injection Molding for Door Frame Kits

Injection Molding for Tunnel connectors

Injection Molding for Support Hoop

Project Challenges

1. Material Weather Resistance and UV Resistance Requirements

The rabbit tunnel system is primarily used outdoors, exposed to sunlight, rain, and weathering conditions. The materials need to maintain strength and functionality over time, avoiding discoloration, aging, and brittleness.

2. Complex Structures and Precision Fit

Components (such as connectors, door frames, and support hoops) typically have complex geometrical structures that must fit precisely. Any slight mold error can affect the functionality and stability of the components during assembly.

3. Durability and Safety Requirements of the Product

As a product intended for pet use, it is essential to ensure durability and safety, preventing any material-related issues that could lead to breakage or other safety hazards.

Our Injection Molding Solutions for Rabbit Tunnel Systems

Material Weather Resistance and UV Resistance Requirements

a. Material Selection: We discussed the usage environment with the client and recommended materials with excellent weather resistance and UV performance, such as ABS (757) + UV and Nylon PA66 (101L) + UV, to ensure strength and functionality under sunlight and various weather conditions.

b. UV Additive Control: We strictly control the proportion of UV additives to ensure uniform mixing of plastic pellets in each batch, enhancing the UV resistance of the components and extending the product’s lifespan.

Complex Structures and Precision Fit

a. DFM (Design for Manufacturability) Analysis: Before project initiation, we conduct detailed DFM analysis to optimize the geometrical design of the components, ensuring they are suitable for the injection molding process and minimizing potential production issues.

b. Precision Mold Manufacturing: We employ advanced processing technologies, including CNC machining, EDM (Electrical Discharge Machining), and wire cutting, polishing to ensure the molds achieve micron-level precision, enabling the produced plastic parts to maintain consistent dimensional accuracy.

Injection Mold for Rabbit Tunnel Systems

Injection Mold for Rabbit Tunnel Systems

c. Strict Tolerance Control: Throughout the production process, our team of experienced quality control specialists strictly adhere to tolerance requirements, especially for the clips and interface parts, to ensure there are no issues of looseness or tightness during assembly. After our products are manufactured, we perform inspections using state-of-the-art Zeiss CMM machines to verify that the dimensions and features are within the tolerances specified by our clients, guaranteeing precise fit and high quality.

Quality Control for Door Frame Kits

Quality Control for Tunnel connectors

Durability and Safety Requirements of the Product

a. Material Testing and Certification: Before mass production, we conduct a series of tests (such as tensile strength, impact, and aging tests) to ensure the components can withstand the wear and tear of daily pet use.

b. Durability Design: During the mold design phase, we strengthen critical areas of the product, such as the connectors and support hoops, to ensure they do not fracture due to stress concentration over long-term use. Additionally, we optimize wall thickness to enhance overall component durability.

c. Surface Treatment and Safety Protection: We polish and refine the mold surface to achieve a YS20023/YS20021 polished finish, eliminating sharp edges or burrs to ensure the safety of rabbits during use. Additionally, we perform durability tests on the components to verify their impact resistance and wear resistance, ensuring long-term reliability and performance.

Conclusion

By leveraging our expertise in ABS and Nylon 66 injection molding, we provided a reliable, efficient solution that enabled the client to bring their innovative rabbit tunnel system to market with confidence. Over the past eight years, we’ve built a strong partnership with this client, receiving consistent yearly orders, and becoming their trusted custom injection molding supplier in China.

Additionally, Alpine Mold offers free mold storage and professional maintenance services. Our dedicated storage facilities are strictly controlled, and we maintain precise records for each mold to ensure that every production run meets the client's specifications. If you have a similar project in mind, please send us your designs, and we’d be happy to collaborate on bringing your idea to life!