Optical Probe From Concept to Reality

Team RPWORLD

fromRPWORLD

29 Jul, 2022

A high-tech company in the field of infrared detection technology research, appointed us for the production of 200 sets of optical probe components. Due to their complex structures and undercut details, injection molding or CNC machining were not feasible.

Injection Molding

- design cycle

- manufacturing systems

- materials

- product design

Project Background

Our client, a high-tech company in the field of infrared detection technology research, appointed us for the production of 200 sets of optical probe components. Due to their complex structures and undercut details, injection molding or CNC machining were not feasible. Local suppliers in North America, were unable to do it unless the design was changed. However, to certify the product functionality, the structure design could not be changed. Thus the client turned to us for help.

Challenges

★ How to select the most suitable manufacturing process to meet the customer’s needs?
★ How to attain the requirements of flame-retardant performance?
★ How to achieve the solid colour, good surface effect and desired mechanical performance for the product?
★ How to guarantee high quality and launch the product as early as possible?

RPWORLD SOLUTIONS

Processes Chosen

• After careful structural analysis, urethane casting was chosen. Besides, mold inserts and sliders were added in the mold design.

Material Selection

• Materials need to have a certain degree of mechanical strength and flame-retardant. Eventually, we chose the UL-94 V0 degree ABS performance polyurethane.

Production Schedule

• Rapid prototyping and testing	4 days
• Silicon mold manufacturing and testing	3 days
• Replication of 200 units by urethane casting	7 days
• After-treatment by specialist	5 days
• Total	30 days

Testimonials

RPWORLD has been extremely helpful with the current round of production parts. Turnaround of the project is very fast and the parts are of extremely good quality with excellent surface finish. This is a valuable factor when planning future development. You are true to your motto “Under Promise, over Deliver”!

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Nikolaus Mroncz

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The injection moulding process is widely used in large volume production as it produces comparatively low scrap production and has high repeatability. The versatility of the injection moulding process demands much broader design considerations. Most of the design considerations will be made on the mould after setting out the product requirements.

Some of the factors that affect the injection moulding design include: how the part will be used (singular product or for assembly), its dimensional and mechanical requirements, and its ability to withstand elements such as chemicals or pressure. Some vital tips to consider when designing for injection moulding are explored below.

1. Carefully choose materials suitable for your design

Different injection moulding materials offer varying properties. For example, some injection moulding materials provide more dimensional stability than others. Similarly, some bond better with adhesives than others. Material design considers the following: temperature, pressure, biological and chemical interactions.

Thermoplastic resins can be broadly classified into amorphous and semi-crystalline. While semi-crystalline thermoplastics offer better chemical and electrical resistance, their amorphous counterparts are much more dimensionally stable and more resistant to impact. Material selection can affect the required tolerance level or certain features, like wall thickness.

2. Take into account the part tolerance

Tolerances are affected by the shrinkage that occurs during the cooling process. Amorphous materials like PLA generally have tighter tolerances than semi-crystaline materials like PEEK.

Tight tolerances make production more expensive, but they may be necessary for your part to fit or function properly, especially if it is used in an assembly.

We recommend contacting your supplier at the design stage to

Plastic Injection Molding Surface Finish Options: Making the Right Choice

Injection molding is an invaluable process for creating plastic parts. This process is fast, cheap, and helps create vast volumes of identical objects. One of the most significant advantages of injection molding is the natural surface finish of molded parts. Even without any injection molding surface finish or post-processing treatment, molded parts have smooth surface finishes suitable for many end uses.

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Injection molding is an invaluable process for creating plastic parts. This process is fast, cheap, and helps create vast volumes of identical objects. One of the most significant advantages of injection molding is the natural surface finish of molded parts. Even without any injection molding surface finish or post-processing treatment, molded parts have smooth surface finishes suitable for many end uses.

Simple pre-coloration of plastic pellets means that molded parts sometimes don’t require any painting or tinting after fabrication. Nonetheless, the vast range of injection molding applications means that injection molded parts often need some form of surface finishing. It may be a quick polish or something more comprehensive.

Some companies will demand very smooth plastic surface finish types for aesthetic reasons. Others may prefer a high level of roughness to extend a part’s lifespan or plastic glossy texture. This guide describes some of the available SPI surface finish options for injection molded parts, with advice for specific materials.

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There are several surface finish options for custom parts, including injection molded plastic parts. Surface finishing procedures for injection molding can help to either increase or decrease the roughness of a part. Plastic glossy texture may be preferred for aesthetic parts such as toys. On the other hand, rougher finishes may be best for certain mechanical parts or to reduce overall costs.

The Society of Plastic Industry (SPI) established industry standards for plastic injection molding surface finishes and features. The SPI finish designation relates to the aesthetic qualities of plastics for injection molded parts. There are 12 standard plastic surface finish types, according to the SPI.

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