Injection moulding plc controller

In addition, our company has established cooperative relationships with plastic raw material suppliers, printing manufacturers, etc. to ensure the supply of raw materials and printing quality. Through our rich experience and perfect supply chain, our company can provide customers with high-quality customized injection moulding plc controller products to meet their specific needs. At the same time, we have 10 years of professional foreign trade service experience, understand the foreign trade process, and better serve our customers. For injection moulding plc controller products, we can make corresponding plastic parts, which is mainly done through injection molds.

The injection molding process for PLC controllers is essentially divided into two parts: 1. Injection molding of the PLC controller housing; 2. Assembly and testing of the internal electronic components.

Since your core focus is "injection molding," we will focus on the housing injection molding process and briefly explain how it integrates with internal assembly.

Part 1: The Injection Molding Process for PLC Controller Housings

This is a core step that demonstrates your technical prowess as an excellent mold maker. Unlike ordinary consumer products, PLC housings have extremely high requirements for strength, precision, flame retardancy, protection levels (such as IP20, IP67), and electromagnetic shielding (EMI).

Phase 1: Design & Material Selection

Structural Design:

Uniform wall thickness: Typically 2.5-3.5mm to ensure strength and prevent shrinkage.

Reinforcement Ribs: Extensive reinforcement ribs are used to improve impact resistance and deformation resistance, while adhering to the "60% wall thickness" principle to prevent shrinkage.

Clips and Mounting Points: Precision-designed clips and supports secure PCBs, modules, and terminals, ensuring smooth assembly and reliable connections.

Sealing Structure: For high protection ratings (such as IP67), design sealing ring grooves and ultrasonic welding lines.

Material Selection (Extremely Critical):

Flame-Retardant Materials: UL94 V-0 flame-retardant materials must be used, a rigid safety standard for industrial electrical systems.

Common Materials:

PC (Polycarbonate): High strength, high impact resistance, and high heat resistance. Transparent versions can be used for display windows.

PC/ABS Alloy: The most common choice, combining the heat resistance and strength of PC with the processability of ABS.

PBT (Polybutylene Terephthalate): Excellent electrical properties, heat resistance, and chemical resistance.

Additives: Antistatic agents and metal fibers/coatings are often required to achieve electromagnetic shielding (EMI/RFI).

Phase Two: Precision Mold Design & Manufacturing

PLC housing molds are the epitome of high-precision, multi-action molds.

Mold Steel: High-quality, hard, and wear-resistant steel (such as S136 and NAK80) must be used and heat-treated to ensure long life and high precision.

Hot Runner System: Standard configuration. A needle-valve hot nozzle ensures balanced filling in large, multi-cavity molds. No handles are required, saving expensive raw materials.

Complex Undercut Processing:

Multiple sliders and lifters are used to handle the numerous undercuts around the housing, such as clips and wiring holes.

High-Gloss Surface/Texture:

Exterior surfaces typically require a high-gloss polish or fine texture (etching) to enhance the quality of industrial products and conceal minor scratches.

Cooling and Exhaust: A uniform and efficient cooling system is designed to minimize deformation. Precision exhaust slots are provided to prevent trapped air and burning.

Stage 3: Injection Molding Process

The process tuning goals are dimensional stability, low internal stress, and performance that meets specifications.

Strict Drying: Materials such as PC and PC/ABS must be dried at 100-120°C for at least 3-4 hours to prevent hydrolytic degradation and silver streaks.

High Mold Temperature: Utilize a higher mold temperature (e.g., 80-100°C) to reduce internal stress, improve surface gloss, and enhance the material's flame retardancy and mechanical properties.

Medium-Slow Injection Speed: Utilize medium-low injection speeds to prevent excessive shear stress from causing material decomposition (especially decomposition of flame retardants), which could affect flame retardancy and mechanical properties.

Sufficient Holding Pressure: Apply sufficient holding pressure and time to compensate for shrinkage, ensure dimensional accuracy and structural strength, and prevent insufficient strength in critical areas such as snap fasteners.

Stage 4: Post-Processing & Quality Control

Post-Processing:

De-gating: Automated by a robotic arm.

Ultrasonic Welding: Ultrasonic welding fuses the upper and lower covers together to achieve a high level of dust and water resistance (IP67).

**Rigorous Quality Inspection (Extremely Strict)**:

Full Dimension Inspection (CMM): A three-dimensional coordinate measuring machine (CMM) is used to perform full dimensional inspection of key mounting points and snap-in locations.

Functional Fitting: Test assembly with internal components such as the PCB and terminals to ensure a perfect fit.

Flame Retardancy Testing (UL94 V-0): Sampling undergoes rigorous flame retardancy testing, a mandatory safety threshold.

High and Low Temperature Testing: Tests the housing's deformation and impact resistance at high and low temperatures.

Ingress Protection Rating Testing (IP Testing): Tests the IP rating using specialized dust and water resistance testing equipment.

Part II: Internal Assembly and Assembly Process

This isn't necessarily a service offered by injection molding plants, but excellent manufacturers offer this "one-stop" service.

SMT (Surface Mounting) (SMT): Mounts resistors, capacitors, chips, and other components onto PCBs.

DIP (Dip-Insulator) (DIP): Mounts larger electronic components.

Conformal Coating: PCBs are sprayed with a protective coating to protect against moisture, corrosion, and dust.

FINAL Assembly: The PCB, terminals, power module, and other components are installed in the injection-molded housing and sealed with screws or ultrasonic welding.

Programming and Burn-in Testing: The program is loaded and long-term power-on burn-in testing is performed to eliminate premature failures.

We are a injection moulding plc controller manufacturer, providing high-quality injection moulding plc controller manufacturing. As long as you want to customize/develop injection moulding plc controller products, you can find us. We have professional injection mold design and mature manufacturing technology, providing you with one-stop service, from product design-mold making-product production-product packaging-product transportation, we can help you in every link. As long as you come to us, we will provide you with the ultimate service and satisfy you in terms of product quality, production time, information dialogue, etc.

Plastic Injection Mould making

Plastic molding specifications

Mold design:

Transaction process:

Mold testing:

Product packaging

Factory

We are Custom Plastic Mold factory. Our factory is plastic injection mold maker. we has 17 years of experience in professional custom plastic mold and 10 years of foreign trade experience. We are custom Plastic Mold supplier. We can provide custom Plastic Mold service. Our factory can make the Injection molded plastic parts, and the quality of the products will satisfy you.

We have more than 50 high-end machines and hundreds of engineers and designers. We can provide one-stop service, from product design - mold making - product production - product packaging - transportation. We have a complete production chain. We can meet all your requirements.

Services we provide:

Professional custom mold service, Plastic mold design and manufacturing .plastic product production, product design, mold design, blow mold customization, rotational mold customization, die-casting mold customization. 3D printing services, CNC manufacturing services, product packaging, customized packaging, shipping services.

We always adhere to the principles of quality first and time first. While providing customers with the highest quality products, try to maximize the production efficiency and shorten production time. We are proud to tell every customer that our company has not lost any customer since its establishment.If there is a problem with the product, we will seek a solution actively and take responsibility to the end.

FAQ

Q1: Are you trading company or manufacturer ?

A: We are manufacturers.

Q2. When can I get the quotation?

A: We usually quote within 2 days after we get your inquiry.

If you are very urgent, please call us or tell us in your email so that we can quote for you first.

Q3. How long is the lead-time for mold?

A: It all depends on the products' size and complexity. Normally, the lead time is 25 days.

Q4. I have no 3D drawing, how should I start the new project?

A: You can supply us a molding sample, we will help you finish the 3D drawing design.

Q5. Before shipment, how to make sure the products quality?

A: If you don't come to our factory and also don't have the third party for inspection, we will be as your inspection worker.

We will supply you a video for production process detail include process report, products size structure and surface detail, packing detail and so on.

Q6. What is your payment terms?

A: Mold Payment: 40% deposit by T/T in advance, 30% second mold payment before sending out the first trial samples, 30% mold balance after you agree the final samples.

B:Production Payment: 50% deposit in advance, 50% before sending out the final goods.

Q7: How do you make our business long-term and good relationship?

A:1. We keep good quality and competitive price to ensure our customers benefit for best quality products.

2. We respect every customer as our friend and we sincerely do business and make friends with them, no matter where they come from.