steering wheel injection 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 steering wheel injection 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 steering wheel injection moulding products, we can make corresponding plastic parts, which is mainly done through injection molds.

The core points of steering wheel injection molding, combined with safety regulations, ergonomics and process characteristics, are summarized into five key control modules:

1. Material selection and pretreatment

Substrate requirements

High rigidity + impact resistance balance: commonly used PP+EPDM-T20 (20% talc reinforced polypropylene), bending modulus must be ≥2200MPa, impact strength>15kJ/m² (-30℃ test).

Weather resistance and environmental protection: must pass UV aging test (1500 hours color difference ΔE <3) and volatile organic compound VOC test (formaldehyde <10μg/g).

Process influence: Material fluidity (MFR 20-35g/10min) directly affects the filling effect.

Metal insert pretreatment

Degreasing and rust removal: alkaline cleaning + sandblasting (Sa2.5 level), improve plastic-metal bonding strength>15MPa.

Preheating control: Preheating at 120-150℃ eliminates the difference in shrinkage between hot and cold and prevents stress cracking (the risk of cracking increases by 70% when the temperature difference is greater than 80℃).

2. Core elements of mold design

Hot runner system optimization

Needle valve sequence control: Ensure gradient filling from the spoke to the rim (reduce the appearance of weld lines in the gripping area).

Cooling water channel layout: The conformal water channel is ≤15mm from the cavity surface, and the temperature difference is controlled within ±3℃ (avoid shrinkage marks on the leather surface).

Venting and ejection design

Segmented exhaust: 0.02mm stepped exhaust grooves are set at the deep rib position (total cross-sectional area > 0.03% of the cavity projection area).

Nitriding ejector pin: H-shaped layout avoids deformation, surface hardness ≥1000HV (resist glass fiber wear).

3. Injection molding process window control

Melt temperature, 220-250℃, >260℃ will cause material degradation

Injection pressure, 80-120MPa, insufficient pressure will cause metal insert coating failure

Pressing pressure, 60% of injection pressure, too high will cause overflow and internal stress

Cooling time, 40-60s, 30% decrease in dimensional stability when <35s

Mold temperature, 60-80℃, <50℃ leather grain transfer is not clear

Special process application:

Variable mold temperature technology: the mold surface rises to 110℃ before injection (improves leather grain effect), and drops to 40℃ during the cooling stage (shortening cycle).

Micro-foam injection molding: supercritical N₂ injection pressure of 25MPa, 15% weight reduction and elimination of shrinkage marks (special sealing mold required).

4. Defect prevention measures

Weld line control

Adjust the gate position to make the fusion line deviate from the high stress area (such as the connection between the spoke and the rim).

Use in-mold rotation technology (mold rotates 15° for secondary injection molding to shift the weld line).

Countermeasures for poor coating

Metal inserts are designed with a hook structure (depth 0.3-0.5mm, angle 45°).

Use high-pressure delayed switching (HPLC): 120MPa high pressure is maintained until the gate is closed.

V. Post-processing and testing standards

Dimensional stability control

Placed in a constant temperature and humidity environment (23℃/50%RH) for 48 hours for measurement, radial runout ≤0.8mm.

Use laser scanning to compare 3D digital models (tolerance band ±0.25mm).

Safety performance verification

Static torque test: >150N·m without permanent deformation (national standard GB 11557).

Fatigue test: No cracks after 1 million times of ±45° torsion (load 50N·m).

Industry cutting-edge trends (2025)

Application of bio-based materials: PE extracted from sugarcane ethanol (carbon footprint reduced by 60%), which has passed Volkswagen TL52696 certification.

AI process optimization: Use machine learning to predict the weld line position (accuracy > 92%) and adjust process parameters in real time.

Integrated molding: Inserts embed sensors (torque/heart rate monitoring), and injection molding simultaneously completes circuit packaging.

Key summary: The essence of steering wheel injection molding is a precise balance between safety and comfort. From insert processing to fatigue testing, every link must implement the "zero tolerance" concept - 0.1mm weld line misalignment may lead to the risk of fracture in 10 years. Future technology will evolve in depth towards functional integration and low-carbon manufacturing.

steering wheel injection moulding

We are a steering wheel injection moulding manufacturer, providing high-quality steering wheel injection moulding manufacturing. As long as you want to customize/develop steering wheel injection 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.