Worm gear 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 worm gear 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 worm gear injection moulding products, we can make corresponding plastic parts, which is mainly done through injection molds.

The injection molding of worm gears requires extremely high precision, material properties, and mold quality. Because worm gears are transmission components, their tooth profile accuracy, wear resistance, and strength are directly related to the performance of the entire transmission system.

The following is a detailed worm gear injectionmolding process, highlighting key differences from conventional injection molding (such as for shopping baskets).

The Complete worm gear injectionMolding Process

The entire process revolves around precision and performance.

Phase 1: Material Selection and Preparation

This is the first and fundamental step in the success of worm gear injectionmolding. Improper material selection can hinder all subsequent processes.

Common Materials:

Polyoxymethylene (POM / DuPont Delrin®): The most preferred material. It offers exceptional strength, rigidity, fatigue resistance, and wear resistance, a low coefficient of friction, excellent self-lubrication, and excellent dimensional stability.

Nylon (PA66, PA46, and glass-reinforced nylon): Excellent toughness, strength, and wear resistance. Adding glass fiber (such as PA66+GF30) can significantly improve its strength, rigidity, and heat deflection temperature, making it suitable for applications with higher loads.

Polyetheretherketone (PEEK): Used in applications with extremely high requirements (such as high temperature and high strength), but is very expensive.

Material Handling:

Drying is essential! Both POM and nylon are hygroscopic. Before injection molding, they must be dried in a forced air oven strictly according to the material supplier's specified temperature and time (e.g., drying POM at 80-90°C for 3-4 hours). Otherwise, the product will develop silver streaks, bubbles, and a significant decrease in strength.

Phase Two: Mold Design & Manufacturing

Worm gear molds are high-precision molds, and their core lies in the machining of the tooth-shaped cavity.

Mold Material: High-strength, high-wear-resistant, high-quality mold steel (such as ASSAB 718 from Sweden and NAK80 from Daido, Japan) must be used and quenched to ensure dimensional stability during long-term production and resist wear from the plastic melt.

Cavity Machining: The worm gear tooth profile is typically formed using precision electro-discharge machining (EDM). This requires the use of ultra-high-precision copper electrodes, which are themselves machined using CNC wire-cutting to ensure accurate tooth profile replication.

Gating Design: To avoid affecting tooth profile accuracy and creating weld marks, pin-point gates or submarine gates are typically used. Gates are typically located on the gear end face or shaft hole, never on the tooth surface.

Cooling System: A uniform and efficient cooling water circuit must be designed to ensure a constant mold temperature, minimizing deformation caused by uneven shrinkage and ensuring accurate pitch and tooth profile.

Ejector System: Ejectors must be located in non-working areas, such as ribs and shaft holes. They must never contact the tooth surface, as this can damage the tooth profile or cause white spots.

Venting System: Proper venting slots must be provided at the end of the tooth profile, where the melt is last filled. Otherwise, trapped air can lead to defects such as burning and underfill.

Stage 3: Injection Molding Process

This is the core step in transforming the material into a product, and the process parameters require extremely precise adjustment.

Clamping & Injection:

The mold is closed, generating sufficient clamping force.

The screw injects the plasticized molten plastic into the mold cavity at a medium-to-low speed. High speed and high pressure are not recommended, as this can easily cause internal stress, flash, and overfilling of the tooth profile.

Holding & Cooling:

The holding stage is crucial. Appropriate holding pressure and time are applied to compensate for plastic shrinkage during cooling, preventing shrinkage and sinking in the product and ensuring a full and dimensionally stable tooth profile. The holding pressure and time require optimization through multiple trials.

The product is fully cooled and formed within the mold. Sufficient cooling time is essential, otherwise deformation during ejection is likely.

Mold Opening & Ejection:

The mold opens, and the ejection system ejects the molded worm gear from the mold cavity.

Phase 4: Post-Processing & Quality Inspection

Post-Processing:

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

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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.