High Quality Wall Switch Panel Injection Molding

Name: Switch Panel Mold, Wall Switch Mold, Wall Switch Panel Mold Our Services: Mold making (CNC/EDM); Plastic injection molding Mold steel: S136 HRC 48-52Parts Materials: PC Lexan 945U/ PC ML-4120ZHP  Color: White(RAL 9003); Black(9004); White translucency

Project Overview

Client: US-based company specializing in intelligent switch shells and control panels

Industry: Electronics, Switch Panels
Year of Collaboration: 2018 (initial project)

We had the privilege of partnering with a renowned US-based client to develop high-quality wall switch panel molds and produce wall switch panel Injection Molding. The collaboration began when the client visited our facility in China to initiate a custom project for intelligent switch shells. Their detailed product designs and technical expertise facilitated a smooth and efficient process. The initial order of 3,000 units exceeded their quality expectations, leading to a significant increase in order volume.

Product Requirements and Material Solutions

The wall switch panel consists of three parts that require precise assembly:

•  Base shell

• Upper shell

• Internal partition

To meet the customer's demand for a white translucent component, we recommended Lexan polycarbonate (PC) with light-diffusing properties. This material ensures excellent transparency after assembly, enhancing the visual appeal and functionality of the panel.

Key Material Features of  Lexan polycarbonate (PC):

• Light diffusion: Provides uniform light transmission

• UV-stabilized: Ensures long-term durability under various environmental conditions

• UL-94 V0 fire rating: Self-extinguishes within 10 seconds when exposed to an open flame, without dripping or emitting harmful chlorine fumes

High-Durability Mold Steel Selection

To ensure the wall switch panle molds' longevity and consistent performance, we used S136 steel, known for its:

• Exceptional corrosion resistance

• High polishability for excellent surface finishes

• Outstanding wear resistance for extended mold life

• Superior machinability for complex mold designs

These properties make S136 steel ideal for high-precision plastic injection molds, especially those requiring durability and resistance to demanding environments.

Precision Injection Molding Process

We produced three custom injection molds for this wall switch panel project, covering the:

1. Wall switch shell base

2. Upper shell

3. Internal partition

All parts were crafted using Lexan polycarbonate, with different pigments to achieve a range of finishes, including translucent, white, and black.

Transparent Part Manufacturing

For the central transparent section, we used specialized light-diffusing materials and applied localized tanning treatments to meet aesthetic and functional requirements. The result was exceptional transparency and customer satisfaction.

Safety and Compliance

The Lexan 945U material used in these enclosures offers:

• Excellent electrical insulation properties

• UV stabilization for enhanced durability

• UL-94 V0 fire safety rating: Self-extinguishes quickly without harmful emissions or dripping plastic

These safety features ensure compliance with international standards, making the product suitable for high-performance electrical applications.

Customer Satisfaction and Results

Our dedication to precision, quality, and customer service exceeded the client’s expectations, resulting in highly positive feedback and a commitment to future projects. Our comprehensive approach to mold design, material selection, and injection molding ensured a successful outcome that met and surpassed their requirements.

Do you need high-quality custom molds for electronic or switch panel applications? Contact us today for a tailored solution. We provide precise mold manufacturing and injection molding services designed to meet your specific needs. Get in touch for a detailed quotation and discover how we can support your next project!