Longsheng

2. Sistema di sviluppo dello stampo di precisione

• Equipaggiamento di lavorazione a micro-scarico EDM (risoluzione degli elettrodi 0,002 mm).
• Mirror polishing process (Ra ≤0.05μm).
• Thermal flow channel temperature control system (±1℃ temperature stability).
• JS technology: 95% of projects meet ultra-high precision standards, with a rich experience in mold design optimization.

3.Advanced Testing Equipment Unit

• 3D blue light scanner (measurement accuracy ±0.002mm).
• On-line optical detection system (OCR/OCV recognition rate ≥99.9%).
• Microscopic metallographic analyzer (surface roughness detection up to nanometer level).
• JS technology: A team with 20 years of engineering experience providing full process quality control.

4.Automated production systems

• Mechanical arm lifting device (positioning accuracy ±0.005mm).
• Mould labeling system (labeling tolerance ±0.01mm).
• Smart warehouse management system (20% increase in inventory turnover efficiency).
• JS technology: 98% of orders are delivered on time and provide customized automation solutions.

5.Special Material Processing Equipment

• Microfoam injection molding device (cell diameter ≤50μm).
• Nanocomposite agitation system (dispersion uniformity ≥95%).
• Medical-grade clean injection molding chamber (ISO 7 environmental control).
• JS technology: More than 50 years experience in material processing, medical/electronics field.

JS company combines micro-injection molding machines, wire cutting equipment and Moldex3D simulation system to form a full-chain technology loop from molding design to precision plastic molding. Typical manufacturing case of micro parts: precision gear injection yield of 0.5mm diameter was 99.2% and dimension tolerance was controlled to ±0.003mm, demonstrating the progressiveness of the equipment system.

How to achieve the combination of multiple material injection molding?

1.Material selection and compatibility treatment

• Material performance match: Choose materials with similar thermal expansion coefficients and shrinkage (e.g. hard ABS and flexible TPU) to avoid interface cracking caused by temperature change.
• Surface pretreatment: The adhesion between materials is enhanced by plasma treatment, chemical coating or mechanical polishing, such as nano coatings activated material surfaces when metal and plastic are bonded.

2.Mold design and manufacture

• Two-color/multi-cavity molds: Using rotary molds, slide mold or laminated mold structure to achieve precision injection molding of different materials in different regions. Two-color molds, for example, switch the gate on and off by rotating it 180 degrees and injecting two types of melt.
• Optimization of gate and flow path: Design of an independent gate system to prevent material mixing and contamination while ensuring melt flow balance (e.g. use of hot flow path technology to reduce waste of cold heads).

3.Injection molding process parameter control

• Multi component injection molding machine: Independent injection units equipment, control temperature, pressure and injection speed respectively. For example, a hard material is first injected as a skeleton, then filled with soft glue to form a buffer.
• Time-temperature coordination: Precise control of injection and retention times of different materials to ensure adequate interface fusion.

4.Interface integration technology

Mechanical interlock design: Design of a concave or inverted structure in a die to improve bonding strength through physical interlocking.

Chemical Adhesives Precoating: Special adhesives are sprayed on the surface and cured by injection molding with high temperature activation to achieve molecular level bonding (suitable for dissimilar materials).

5.Quality inspection and reprocessing

• Online monitoring system: Use visual inspection or ultrasonic scanning to verify the integrity of the interface and eliminate product layers or defects.
• Annealing and surface treatment: Removal of internal stress through heat treatment and optimization of appearance and durability (e.g. surface coating of waterproof seals) using processes such as spraying and plating.

What are the common difficulties in injection molding?

In the process of injection molding, due to the influence of material properties, process parameters and equipment accuracy, the following technical problems are often encountered:

1.Material shrinkage control

• Difficult point: Different plastics have different shrinkage rate in the cooling process, it is easy to lead to size deviation.
• JS solution: Optimize mold design with ±0.005mm precision machining technology combined with material science experience to ensure stability of finished product dimensions.

2.Warp and twist

• Difficulty: Uneven cooling or residual stress causes parts to deform.
• JS solution: Adopt advanced cooling system and process simulation technology to balance temperature field distribution and reduce internal stress.

3.quality defects

• Difficulties: Welding marks, shrinkage marks, or pores affect appearance and function.
• JS solution: The surface smoothness is improved by high-precision mold polishing (Ra <0.1μm) and process parameter optimization (pressure/ velocity/temperature).

4.Multi cavity mold balance

• Difficulties: Uneven filling multi-cavity products leads to poor batch consistency.
• JS solution: CAE simulation used to analyze channel balance and customize heat flow system to ensure synchronous filling of each cavity.

5.Risk of material degradation

• Difficulties: Plastic decomposes, changes colour or weakens easily at high temperature and pressure.
• JS solution: Real-time monitoring of screw speed and back pressure with antioxidant additives to ensure stable material performance.

JS company's technological advantages

Typical Case Reference

• Automotive sensor housing: Made of PA66+GF30 material and integrated with metal inserts in mold injection molding, it achieves an IP67 protection level yield rate 99.8%.
• Medical syringe components: Resolves the problem of PP material sticking to the mold by using dust-free workshops and plasma treatment technology, in compliance with FDA biocompatibility standards.

How can JS reduce injection molding production costs by 20%?

• Process optimization: 98% of orders are delivered on time or in advance, automated production lines shorten delivery cycles by 15%, and precision processing reduces waste losses.
• Precision manufacturing: ±0.005mm accuracy reduces rework rate and CAE simulation reduces trial mold cost.
• Rapid response: 24-hour quotation+fast production, flexible scheduling, small order, avoiding redundancy costs in mass production.
• Smart Match: 50+material selection, cost reduction, custom craftsmanship, balanced quality and price.
• Expert support: Our team has 20 years of experience in optimizing design, reducing materials, monitoring the process and eliminating waste.
• Green production: Energy consumption of energy-saving equipment reduced by 15%, material recycling and reuse cost reduction, efficiency.

Actual results:

• Reduce customer costs by 20%: Through these initiatives, JS helps customers save an average of 20% of their manufacturing costs while increasing project efficiency by 25%.
• Long-term cooperative advantage: Cost advantage translates into customer stickiness, 25% increase in return rate.

Summary

Injection-molding is the core technology of modern industry. By melting and solidifying molding plastic material, the production of simple rigid member to complex elastic member is diversified. Whether it is the efficient mass production of thermoplastic or the precise flexible molding of liquid silicone, its process adaptability covers many fields such as automobile, medical treatment and electronics. With its ±0.005mm precision mold design multi-material compatible processing, and automated production line integration integration capabilities JS Company continues to push the boundaries of precision and efficiency injection molding field, providing global customers with one-stop solutions from prototype development to mass production, enabling industry transformation and upgrading for high value added and sustainable development.

Disclaimer

The content of this page is for informational purposes only.JS SeriesNo representations or warranties of any kind, express or implied, are made as to the accuracy, completeness or validity of the information. It should not be inferred that the performance parameters, geometric tolerances, specific design features,material quality and type or workmanship that the third-party supplier or manufacturer will provide through the jusheng network. This is the responsibility of the buyerAsk for a quote for partsto determine the specific requirements for these parts.please Contact us Learn more information.

JS Team

JS is an industry-leading companyFocus on custom manufacturing solutions. With over 20 years of experience serving more than 5,000 customers,we focus on high precisionCNC machining,Sheet metal fabrication,3D printing,Injection molding,metal stamping,and other one-stop manufacturing services.
Our factory is equipped with more than 100 state-of-the-art 5-axis machining centers and is ISO 9001:2015 certified. We provide fast, efficient and high-quality manufacturing solutions to customers in more than 150 countries around the world. Whether it's low-volume production or mass customization, we can meet your needs with the fastest delivery within 24 hours. chooseJS TechnologyIt means choosing efficiency, quality and professionalism.
To learn more, please visit our website: jsrpm.com

FAQs

1.The influence of mold temperature on the quality of injection molded parts?

The mold temperature is too high, which leads to deformation of injection molding, and the surface roughness or internal stress concentration. Accurate adjustment to material characteristics (e.g. 50-80°C for ABS) are required to ensure size accuracy and appearance quality.

2.What are the commonly used types of injection molding machines? ​

Commonly used injection molding machines types are plunger type, screw type and screw pre-formed plunger type. Among them, screw plastic has become mainstream for its efficiency and energy saving and has been widely used in the mass production of plastic products.

3.What problems can high injection pressure cause?

Excessive injection pressure can lead to flash flooding (overflow), increase mold wear, and even lead to deformation or cracking of the product, as well as increased load and energy consumption of the equipment.

4.How to choose suitable injection molding materials? ​

Consider the the product's intended use (PC strength, TPU elasticity), processing temperature and costs such as PP's high temperature resistance, TPU's flexibility, ABS's balance performance and cost.

Resources

Injection molding machine

Acrylonitrile butadiene styrene

Design of plastic components