Scrambler custom part moulding

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 scrambler custom part moulding 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 scrambler custom part moulding products, we can make corresponding plastic parts, which is mainly done through injection molds.

The parts process of a custom frequency scrambler (usually referring to communication security equipment) far exceeds the core of general precision injection molding. It is a systematic engineering that integrates "high-frequency electronic engineering", "ultimate electromagnetic shielding" and "high-reliability structural design". The goal is not only to create a shell, but also to build a "Faraday cage" that can ensure the stable and confidential operation of the high-speed digital circuits and RF circuits inside.

�� Core process: from electronic requirements to physical implementation

The entire process is centered around the principle of "electrical performance-driven structural design" and can be divided into the following four key stages:

Phase One: Deep collaborative design of electronics and structure

This is the cornerstone of all work. Mechanical engineers must work in tandem with radio frequency (RF) engineers and PCB layout engineers from the conceptual stage.

Define core constraints: Clearly define the PCB size, heat generation of the chip, antenna position, type and position of RF connectors (such as SMA heads), heat dissipation requirements, and most crucially, the electromagnetic compatibility level.

Shielding cavity design: This is the core of structural design. The interior of the enclosure needs to be planned into multiple independent shielding compartments to isolate digital circuits, analog circuits, RF circuits and power supplies, preventing mutual interference. The connection between compartments requires the design of a precise grounding spring piece or conductive gasket installation structure.

Heat dissipation and signal integrity: Under the premise of shielding, plan efficient heat dissipation paths (such as the contact surface of thermal grease gaskets and the design of heat dissipation teeth). When all high-speed signal lines and RF traces pass through partition walls, shielded filter connectors or specially designed via structures must be used to prevent electromagnetic leakage.

Phase Two: Selection of Key Materials and Special Processes

The selection of materials directly determines the shielding effectiveness and reliability.

Shell material

Preferred solution: Aluminum alloy (such as 6061, 5052). Complex and precise structures can be achieved through CNC machining, and its excellent electrical conductivity can be utilized to realize overall shielding. The surface is treated with conductive oxidation.

High-strength/complex parts solution: Use zinc-aluminum alloy for die-casting, followed by copper and nickel plating to achieve high shielding efficiency (SE).

Low-cost/lightweight solution: Vacuum coating (sputtering) of conductive layers is applied to the inner walls of ABS/PC plastic, but the shielding performance and durability are usually lower than those of metal solutions.

Connection and sealing

The joint surface of the shell should be designed with installation grooves for conductive sealing strips or metal wire mesh gaskets.

Shielding glass or metal filters should be used at the buttons and interface openings.

Clean metal lap surfaces should be designed around all screw holes to ensure that the resistance between the two parts of the housing is extremely low (usually at the milliohm level) after the screws are tightened.

Phase Three: Precision Manufacturing and System Integration

Precision machining: The metal housing mainly adopts high-precision CNC machining to ensure flatness, screw column accuracy and installation tolerance of RF connectors. Die-castings require precise molds.

Surface treatment and secondary processing: Conductive oxidation is carried out on aluminum alloy after processing. The key contact surfaces may need to be additionally gold-plated or silver-plated to reduce contact resistance. Then install all the accessories such as the conductive gasket, grounding spring, and shielding filter screen.

System pre-assembly: Before the PCB is installed, a conductivity continuity test of the shell must be conducted to ensure that the lap resistance between each shielding compartment complies with the design specifications.

Phase Four: Rigorous testing and verification

This is the final checkpoint to verify whether the scrambler parts are qualified, far from the ordinary appearance and size inspection of the parts.

Environmental reliability testing: It includes high and low temperature cycling, damp heat, vibration and shock tests to ensure that the structure does not deform and the shielding does not fail in harsh environments.

Electromagnetic compatibility testing

Shielding effectiveness test: The assembled empty shell is tested in an anechoic chamber for its shielding ability against external radio frequency interference and its suppression ability against internal signal radiation.

System-level EMC testing: After the PCB is installed, the radiated emission and immunity tests of the entire machine are conducted to verify whether the design meets the national military standard (GJB), MIL-STD-461 or FCC/CE standards, etc.

Long-term electrical performance monitoring: During the temperature cycle and vibration processes, continuously monitor the impedance of the key signal path and the grounding resistance of the shielding cavity to ensure stable electrical performance.

�� Key points and partner selection

The core contradiction: Always seeking a balance among "optimal shielding effectiveness", "heat dissipation efficiency", "structural strength/weight" and "cost/manufacturability".

Design iteration: This process is highly dependent on simulation-driven. Before mold opening or processing, electromagnetic simulation software (such as CST, HFSS) must be used to simulate and optimize the design of the shielding cavity.

Partner: Never choose a manufacturer that only understands injection molding or ordinary CNC. It is necessary to seek suppliers with experience in manufacturing parts for military industry, aerospace, and high-end communication equipment. They should understand concepts such as shielding, grounding, and EMC, and be able to provide corresponding test data and suggestions.

We are a scrambler custom part moulding manufacturer, providing high-quality scrambler custom part moulding manufacturing. As long as you want to customize/develop scrambler custom part moulding 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.

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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.