Polycarbonate Injection Molding for Outdoor Speaker Radiator

Our Services: Mold Flow Analysis, PC Injection Mold Manufacturing, Mass Production Runner System: Hot Runner Standard:HASCO Standard Mold Cavities:1x1 Surface Finish:VDI 30 Mold Material:S136 Plastic Material: PC505RU+fire Proof+ UV+ 10%GF

Project Background

Our client is a product designer from Austria, whose company specializes in designing, manufacturing, and selling various electrical products. In January 2022, the client designed a new outdoor speaker. After finding our website through a Google search, the client contacted us via email, seeking assistance in customizing a radiator enclosure for the outdoor speaker. Upon signing a confidentiality agreement with the client, they provided us with 3D drawings in STEP format and detailed information about the plastic material, required quantity, and surface treatment for the project. Upon receiving the client's drawings, we provided a quotation within 24 hours.

Choosing S136 as Mold Material

The customer has selected PC505RU+fire Proof+UV+10%GF material, which has high requirements for the mold steel. To address this, all our engineers held a meeting to discuss and recommend the use of S136 steel. S136 ensures that the mold has sufficient hardness and wear resistance, meeting the molding requirements of PC505RU+fire Proof+UV+10%GF material to maintain production stability and high-quality finished products. Additionally, S136 steel exhibits excellent machinability, which is beneficial for mold manufacturing and maintenance, ultimately enhancing production efficiency and product quality.

Mold Flow Analysis Report

Upon receiving the customer's order, we conducted an initial Mold Flow Analysis to evaluate the runner system, mold performance, and process efficiency based on the provided drawings. After the completion of the Mold Flow Analysis, we provide comprehensive conclusions & suggestions to optimize the overall manufacturing process, ensuring enhanced efficiency and quality outcomes.

Hot Runner System Analysis

Mold Performance Analysis

Mold Performance Analysis

High-Precision PC Injection Mold Manufacturing

Our team of skilled engineers and technicians meticulously designed and manufactured the injection mold for the outdoor speaker radiator enclosure with a focus on precision, especially since the product required assembly with light guide columns. To ensure the precision of the product, we have introduced numerous advanced precision processing equipment. Among these, Alpine Mold is equipped with three sets of Charmilles EDM machines, specifically used to achieve a VDI 30 surface finish during the mold process. Charmilles, a renowned brand from Switzerland, has below advage:

1.High precision machining

2.Creating beautiful and uniform textured surfaces

3. Producing mirror-polished surfaces, eliminating the need for additional polishing in later stages.

Charmilles EDM machines

 Injection Mold for Outdoor Speaker Radiator

PC Injection Molding Mass Production

Once the trial production of the mold for the outdoor speaker radiator enclosure is completed, we send the samples to the customer for inspection and testing. Upon receiving and confirming the samples without any issues, our sales team promptly notifies our injection molding department to commence mass production using the Fancu injection molding machine. Throughout the mass production process, we place great emphasis on strict quality control, including IQC, IPQC, and FQC and our QC team conducts spot checks every 2 hours to ensure the quality standards are met.

Polycarbonate Injection Molding for Outdoor Speaker Radiator

Polycarbonate Injection Molding for Outdoor Speaker Radiator

Conclusion

In conclusion, our collaboration with the client on the design and manufacturing of the outdoor speaker radiator enclosure has been a success, thanks to our great communciation with this client, our team's expertise, precision manufacturing processes, and commitment to quality. With a focus on precision and quality control, we successfully completed the polycarbonate injection mold manufacturing and initiated mass production to deliver the desired outcomes. Our dedication to customer satisfaction and quality assurance remains unwavering, reflecting our ongoing commitment to excellence in the manufacturing industry. If you have any similar projects in the realm of injection molding or tooling, please do not hesitate to contact us. We are ready to bring your ideas to life!