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Views: 56 Author: Danny Luo Publish Time: 2023-10-26 Origin: Site
Our customer is a specialized company that provides various types of crane control systems. In 2021,they designed a new control remote and chose to collaborate with us for the remote control shells. This project requires us to manufacture molds, perform overmolding injection molding, and assemble the whole product based on the customer's design, requirements, and specifications.
Based on the customer's design and requirements, we manufactured three sets of molds, including 1+1, 1, and 1+1 cavities corresponding to different parts of the product.This project consists of five main components: top cover，overmolding，cable clamp，base cover and clip. This product needs to meet the IP66waterproof rating to ensure its normal functioning in harsh environments.
Compatibility information has been requested from these material suppliers, this data is based on standard PC, TPE and PP grades.
1. Achieving excellent adhesion between PC and TPE materials in overmolding
Challenge：Plastic overmolding must have excellent adhesion.It is crucial for PC and TPE materials to adhere well to each other in order to create a durable and reliable remote controller shell.
Solutions：To address this challenge, we have implemented rigorous testing, precise material selection, and optimized overmolding injection molding manufacturing processes. By carefully controlling the material formulations and following proper overmolding injection molding techniques, we aim to achieve a strong adhesion between PC and TPE.
2. Ensuring that overmolding products meet the IP67 waterproof rating
Challenge：Another challenge of the project is to achieve high-quality overmolding injection molding product and ensure that the remote controller shell meets the IP66 waterproof rating. This rating guarantees the shell's ability to withstand water ingress and perform effectively in wet or challenging environments.
Solutions : To achieve the IP66 waterproof requirement, we can perform the following waterproof tests and measures. Before conducting IP66 testing, we performed internal sealing inspections. By observing the sealing areas and interfaces of the encapsulated products, ensure that there are no visible cracks, gaps, or leaks. During IP66 testing, our molding over molding product was fully submerged in water at a depth of 1 meter for 30 minutes while still maintaining normal operation without any damage.
To achieve the matte texture, we utilized various techniques such as chemical etching, bead blasting, or laser engraving on the mold surface. During the injection molding process, the mold's textured surface transfers the desired texture onto the molten plastic material. The textured mold surface creates the corresponding matte texture on the external surface of the remote controller shell.
Quality Control of Critical Dimensions/ Fit Checks
In order to better assemble the overmolding injection molding product, our quality control team conducted the following critical dimensions/fit checks.
1. Assembly of light guide must be so well fit that the parts are watertight to IP66 standard.
2. Holes must allow this screw to pass through and for easy use.
3. This Emergency stop button can be assembled securely enough to pass IP66 testing.
4. All parts fit securely together Refer to assembly file for reference.
