Main Application Fields
Medical and Healthcare: Medical device components requiring extremely high dimensional accuracy, surface quality, and biocompatibility.
Automotive Industry: Engine peripheral components, connectors, sensors, etc., demanding materials with high temperature resistance, chemical corrosion resistance, and high mechanical strength.
Consumer Electronics (3C Products): Aesthetic and structural parts such as mobile phone casings, audio components, game console covers, and digital HD projector housings. These products typically require appealing appearance, lightweight design, and complex structures.
Fiber Optics and Telecommunications: Precision fiber optic connectors, etc., requiring high dimensional stability and low internal stress.
Core Value Delivered
Enhanced Product Quality and Consistency: Through precise process control and defect prediction, defects such as sink marks, warpage, and weld lines are significantly reduced, ensuring high precision and superior appearance of products.
Reduced Development Costs and Cycle:
Fewer Trial Molds: CAE analysis enables early defect prediction, reducing mold modification costs and trial mold attempts for each mold set on average.
Minimized Material Waste: Optimized process parameters and gating systems help reduce rejection rates and material consumption.
Enhanced Design and Manufacturing Capabilities: Enables companies to handle more complex product structures (e.g., products with complex curved surfaces), supports lightweight product design, and optimizes product wall thickness without compromising quality.
Reduced Over-Reliance on Experience: Intelligent design systems and CAE simulation allow less experienced designers to develop reasonable gating systems and process parameters.
Implementation Path and Best Practices
Preliminary Analysis and Design:
Use Moldflow for product manufacturability analysis, evaluating optimal gate locations and initial filling schemes.
Complete detailed design of the gating and cooling systems based on analysis results and intelligent design systems.
Process Parameter Optimization and Validation:
Apply the orthogonal experimental method to design simulation schemes, targeting warpage deformation, volumetric shrinkage rate, etc., and determine the optimal process parameter combination through range and variance analysis.
Conduct final validation of the optimized solution using CAE software before physical trial molding.
Production and Control:
Select injection molding machines equipped with high-precision control systems to ensure stable execution of process parameters.
During production, leverage the control system’s real-time monitoring and quality statistical management functions to track key data and achieve closed-loop quality control.
Summary
The core of ATC-Mould’s precision injection molding solution lies in establishing a full-process closed-loop precision manufacturing system—from design (CAE simulation, intelligent design), optimization (orthogonal experiments, parameter tuning), to production (high-precision control, real-time monitoring). Its value is demonstrated through:
Front-loading Issues: Resolving most potential defects before mold processing through simulation analysis.
Data-Driven Decision-Making: Using orthogonal experiments and variance analysis to shift process optimization from “experience-dependent” to “data-driven.”
Precision Control Throughout the Process: Ensuring process stability, from millisecond-level response of injection molding machines to intelligent temperature control.