Custom Injection Molding for Gas Engine Accessories

Our Services: Plastic mold tool design and build, Plastic Injection Molding 2 Mold cavities: 1*2 2 Part Materials: PET+30%GF Lead Time: L6 weeks Volume: 10,000 parts

About this Client

The customer is a gas engine designer from Germany who specializes in developing and designing efficient gas engines. In 2018, he came to visit our factory and started the first project with us. We have successfully completed more than 10 projects for this client during these years. In 2023, he came to visit our factory again. He was particularly confident with our production strength and cooperated with us another new project about 2 plastic accessories of gas engine.

About the Project

Since this customer had well-crafted 3D drawings of gas engine, and our tooling engineers were able to communicate with him smoothly. This allowed the whole project to progress smoothly and efficiently. This product consists of 2 plastic parts, and we design and manufacturing 2 sets injection molds. Both of them use 1*2 mold cavities. Since the product is used for gas engines, the customer's requirements for the raw material of the product will be relatively high, and all products must not have air holes inside.

Material Character of PET+30%

We recommend PET+30% material for these 2 gas engines covers, and the brand of this material is DuPont. PET+30% is a type of plastic material that is commonly used in the manufacturing of gas engine housings. This material is a composite of PET (polyethylene terephthalate) plastic and 30% glass fiber reinforcement.

The reason why PET+30% material is used for gas engine housings is because of its high strength, stiffness, and dimensional stability. The glass fiber reinforcement in the material provides added strength and stiffness, making it resistant to the high temperatures and pressures that are generated by gas engines. Additionally, PET+30% has good resistance to chemicals and is highly durable, which makes it an ideal material for use in harsh environments such as those found in gas engines.

How we made - Molding to Avoid Air Holes

1. Properly dry the material: Moisture in the material can cause cavitation during the molding process, so our staff will ensure that the PET+30% material is properly dried before it is used in the injection molding process.

2. Create high-quality molds: Our engineers with 30 years of experience in mold design designed 2 sets of molds for these two parts, both with 1*2 cavities, to ensure the plastic material is evenly distributed in the cavities. The molds are made of 718 steel, and our experienced molders use our advanced production equipment to produce high quality molds with a smooth surface, which helps to reduce the appearance of air holes.

3. Controlled Injection Molding Process: Our injection molding operators carefully control the injection molding process to ensure that the material is injected into the mold at the proper temperature and pressure. This also helps ensure that the material flows evenly within the mold and fills all cavities without trapping air.

4. Conduct regular quality checks: Our QC conducts regular quality checks during the molding process to help identify any problems that could lead to air holes. They not only check the size, the appliance, the structure, the assembly and the drop text of the product, but also ensure that all product cannot have air holes. These checks can help to ensure that the process is properly controlled, and any issues are addressed promptly.

Injection Molding Product for Inspection

In order to ensure that all gas engine parts cannot have air holes inside, our quality control (QC) team at Alpine Mold conducts an X-ray inspection of each product. X-ray inspection is a common method used to detect internal defects in plastic parts, including air holes, voids and other defects. X-ray equipment can provide a non-destructive method of inspecting parts without damaging them, making it an ideal method for quality control.

Was this helpful for you?

We hope this case study can benefit your next new project. At Alpine Mold, we offer diverse manufacturing capabilities, such as mold tooling, injection molding and along with other value-added services for prototyping and production requirements. Contact us today.