Injection-molded Components Customization Background

Uwatec, a Swiss client, faced persistent Warpage Control and dimensional accuracy issues when sourcing injection-molded components domestically in Switzerland. These challenges resulted in water leakage and deformation problems in deep-sea diving equipment. Seeking a reliable solution, Uwatec turned to Wingtat for their expertise in overcoming these critical issues.

Project Details:

- Client: Uwatec

- Product Dimensions: 102X208X178

- Material: PA6+50GF

- Mold Cavity:1*1

- Cycle Time: 45 seconds

- Design Period: 5 working days

- Manufacturing Period: 20 working days

- Manufacturing Date: April 2023

Warpage Control Challenges and Solutions：

Warpage Overview:

Warpage in plastic injection molding refers to the deformation of molded parts from their intended shape during the cooling process. It can lead to part folding, bending, twisting, or warping. 

Key Information to Determine Warpage Causes:

1. Degree of Part Deformation: Understanding the extent of part deformation is crucial.

2. Direction of Warpage: Identifying the direction of Warpage aids in developing targeted solutions.

3. Implications for Part Fit Requirements: Assessing how Warpage affects part fit requirements is essential.

Wingtat's Approach:

Uwatec required a flatness of 0.08mm for their injection-molded components. Wingtat utilized Moldflow during the design phase to accurately predict product deformations. Proactive measures, including pre-deformation during mold development, were taken. The collaboration resulted in the successful development of the mold, achieving the desired flatness and delivering excellent results.

Common Warpage Issues and Wingtat's Solutions:

Problem: Insufficient Injection Pressure or Time

If there is not enough injection pressure, plastic material may cool and solidify before the mold is properly packed. Insufficient holding pressure minimizes the packing process. This uncontrolled molecular movement during cooling leads to uneven part cooling rates, causing Warpage.

Wingtat's Solution: Increase injection pressure or holding time.

Problem: Insufficient Dwell Time

Dwell time is the duration resin is heated in the barrel. Insufficient dwell time results in uneven heat absorption throughout the material. Insufficiently heated material hardens and cools before proper packing, causing molecules to shrink at different rates and resulting in Warpage.

Wingtat's Solution: Increase dwell time by extending the cooling process.

Problem: Barrel Temperature Too Low

If the barrel temperature is too low, resin cannot reach the proper flow temperature. If inadequately melted resin is pushed into the mold, it solidifies before molecules properly stack. This differential shrinkage causes Warpage.

Wingtat's Solution: Increase barrel temperature, ensuring uniform melting temperature for the entire injection size.

Injection-molded Components Customization Advantages

Requirement Analysis:

We will have a detailed requirements discussion with you to deeply understand your specific requirements for injection-molded components in terms of function, size, material and appearance. Through comprehensive requirements analysis, we ensure that all details are fully considered.

High-precision mold manufacturing:

We have an experienced mold design team and precision mold manufacturing equipment to ensure the high precision and durability of injection-molded components. This is the key to producing high-quality injection molded parts.

Material selection:

We will recommend and use suitable high-performance plastic materials based on your product application environment and performance requirements. All materials comply with relevant industry standards and regulations to ensure the safety and reliability of injection-molded components.

Delivery and support:

We are committed to delivering products on time and providing a full range of after-sales support. Whether it is technical consultation, product improvement or other service needs, our team will always be there to support you.

Customized solutions:

Based on your specific needs, we provide tailor-made solutions to ensure that each injection-molded component meets your design and functional expectations. Our goal is to help you improve product performance and market competitiveness through high-quality, precision injection molded parts.

Uwatec's collaboration with Wingtat successfully addressed Warpage Control issues, ensuring the production of high-quality injection-molded components for their deep-sea diving equipment. Wingtat's expertise in Moldflow analysis and proactive mold development strategies proved instrumental in achieving the desired flatness and overcoming Warpage challenges.