Challenges Faced by Zhongqing:

1. High-Transparency Material Issues:

   - Difficulty achieving desired transparency in molded components.

   - Instances of fusion lines affecting the surface quality.

2. Molding Fusion Line Control:

   - Fusion lines appearing at convergence points during the injection molding process.

   - Adverse effects on product strength and aesthetics.

3. Large Injection Molding Machine (1200T) Constraints:

   - Inability to meet the production demands efficiently.

   - Hindered the smooth flow of the manufacturing process.

Wingtat's Comprehensive Solutions:

1. Mold Design for Transparency and Fusion Lines:

   - Employed advanced Moldflow simulations for accurate prediction of fusion line locations.

   - Implemented precise timing of sequential hot runners to eliminate transparency and fusion line issues effectively.

2. Addressing Common Molding Issues:

   a. Insufficient Melt Flow:

      - Increased melt temperature to enhance flow characteristics.

      - Accelerated injection speed to prevent melt cooling before reaching convergence points.

      - Elevated mold temperature to minimize melt temperature reduction.

      - Optimized gate design and part thickness to reduce flow resistance.

   b. Air or Volatile Components:

      - Integrated venting through parting lines and designed dedicated venting channels.

      - Ensured effective removal of air or volatile components during the molding process.

   c. Release Agent Impact:

      - Minimized the use of release agents, especially those containing silicon.

      - Mitigated potential issues arising from the interaction of release agents with the melt.

   d. Colorant Influence:

      - Acknowledged challenges in eliminating fusion lines caused by the addition of colorants.

      - Collaborated closely with Zhongqing to optimize colorant choices for improved results.

3. Mold Defects and Structural Modifications:

   - Implemented structural modifications to address persistent fusion line issues.

   - Adjusted gate placement to minimize the visibility of fusion lines.

   - Balanced system parameters to ensure consistent and optimal results.

Project Details:

- Client: Beijing Zhongqing Technology Co., Ltd.

- Product Specifications:

  - Dimensions: 460X680X178

  - Material: ASA-PW978 B

  - Mold Cavities: 1*1

  - Cycle Time: 120 seconds

  - Design Period: 8 working days

  - Manufacturing Period: 45 working days

  - Manufacturing Date: February 2023

Outcomes:

Wingtat's meticulous approach to mold design, process optimization, and structural modifications successfully addressed Zhongqing's challenges. The collaboration resulted in improved transparency, resolved fusion line issues, and enhanced production capabilities, leading to a high level of client satisfaction and confidence in ongoing partnerships.