Custom Plastic Parts for Sweeper Robots

I. Core Material Properties and Application Advantages

(A) Comparison of Mainstream Material Properties

• Wear Resistance: The main brush protective cover must withstand 500 hours of continuous friction testing with a wear amount ≤ 0.3mm.

• Impact Resistance: After dropping from a height of 1m onto a concrete floor, the shell structure remains intact and functions normally.

• Weather Resistance: No significant fading or deformation after 1000 hours of QUV-A irradiation.

• Sensor Installation Precision: The precision of sensor installation parts is controlled within ±0.05mm to ensure accurate sensing.

• Battery Compartment Sealing: The sealing performance reaches IP54 standard, preventing dust and water from entering.

• The density of the body shell material ≤ 1.1g/cm³, reducing the overall weight while ensuring strength and improving battery life.

• Technical Advantages:

• • Supports one-step molding of complex internal structures (such as air ducts, clips) with a dimensional accuracy of ±0.03mm.

• • Multi-cavity mold design (4 – 12 cavities per mold), suitable for 20 – 500g parts, with a production efficiency of 500 – 1500 pieces per hour.

• Process Parameters:

• • Injection pressure: 100 – 160MPa, mold temperature: 50 – 80°C, cooling time: 12 – 20 seconds.

• • Shrinkage control: 0.4% – 0.7% for ABS, 0.5% – 0.8% for PC, ensuring an assembly tolerance ≤ 0.02mm.

• Technical Advantages:

• • Ultrasonic welding achieves seamless sealing, preventing dust leakage and extending the equipment’s service life.

• • Laser engraving enhances the product’s appearance texture and brand recognition.

• Functional Coatings:

• • Wear-resistant Coating: Teflon coating (thickness 15 – 25μm), reducing the friction coefficient by 40%, suitable for components such as rollers and side brushes.

• • Antistatic Coating: Surface resistance ≤ 10⁹Ω, reducing dust adsorption and keeping the body clean.

• Decorative Treatments:

• • Matte Treatment: Surface roughness Ra 0.8 – 1.6μm, with a significant anti-fingerprint effect.

• • Gradient Spraying: Achieves natural color transitions on the body, enhancing product aesthetics.

• Process Advantages:

• • Quickly verifies irregular structures (such as special-shaped side brush brackets, sensor protective shells), with samples delivered within 48 hours.

• • Nylon carbon fiber material with a strength of up to 120MPa, suitable for prototyping high-strength components.

• Application Scenarios:

• • Custom parts for high-end models (order quantity ≤ 200 pieces), reducing the delivery cycle by 50%.

• • Reverse development of parts for obsolete models (3D scanning modeling error ≤ 0.08mm).

• Structural Optimization:

• • Optimizes the air duct structure through ANSYS simulation, reducing air resistance by 20% and increasing suction power by 15%.

• • Designs the tooth depth of the climbing wheels to be 1.2mm, increasing grip by 30% on slopes ≥ 15°.

• Functional Customization:

• • The automatic dust collection port adopts a magnetic sealing design, with disassembly time ≤ 10 seconds and good sealing performance.

• • Leaves a 0.3mm gap in the installation groove of the obstacle avoidance sensor to prevent thermal expansion and contraction from affecting sensing accuracy.

• Main Brush Protective Cover: Selects POM material, which is highly wear-resistant and less prone to wear and deformation during long-term use.

• Body Shell: Adopts PC/ABS alloy, combining high strength and aesthetic appeal to meet impact resistance and appearance design requirements.

• Raw Material Drying: Controls the moisture content of PC material ≤ 0.02% to prevent bubbles and cracks after molding.

• Color Matching Scheme: Achieves a Pantone color matching accuracy of ΔE ≤ 0.8, supporting personalized color customization.

• Rapid Prototyping: 3D printed samples are delivered within 48 hours, with an aluminum mold development cycle of 10 – 15 days (30 – 40 days for steel molds).

• Mass Production:

• • High-speed injection molding line: Equipped with ABB robots, with a daily production capacity of 8000 pieces per device (12-cavity mold).

• • Automated production line: Integrated with a visual inspection system, with a dimensional detection accuracy of ±0.03mm and a defect recognition rate ≥ 99.6%.

• Physical Properties:

• • Wear Test: After continuous rolling for 10km, the wear amount of the rollers ≤ 0.2mm.

• • Impact Test: At -20°C, when a 500g steel ball impacts from a height of 1m, the shell remains intact.

• Environmental Performance:

• • Temperature Resistance Test: After being placed in a 60°C high-temperature environment for 24 hours, the dimensional change rate of components ≤ 0.1%.

• • Dust and Water Resistance Test: IP54 rating, preventing dust and water from entering the equipment.

• Certification Support: Provides CE, FCC, RoHS, and other certification reports to ensure global market access.

• Side Brush Assembly: Injection-molded from wear-resistant POM material, with a brush angle designed at 30°, increasing the cleaning coverage by 25%. The tooth depth of 0.8mm prevents hair entanglement.

• Main Brush Protective Cover: Made of high-hardness PA + GF material, it can withstand a torque of 10N·m without deformation, ensuring the normal operation of the main brush.

• Sensor Housing: Injection-molded from PC material, with a light transmittance ≥ 90%, not affecting sensor signal transmission, and with a protection level of IP65.

• Charging Contact Protective Cover: Made of elastic TPU material, after 100,000 opening and closing tests, the elasticity retention rate ≥ 95%, ensuring charging safety.

• Body Shell: Combines PC/ABS alloy with IMD technology to achieve a high-gloss, wear-resistant surface with a significant anti-fingerprint effect.

• Dust Box: Made of transparent PC material, with clear capacity markings. The snap-fit design enables easy disassembly and good sealing performance.

• Components for Quiet Sweeper Robots: Wraps the air ducts with special sound-absorbing materials, with an operating noise ≤ 50dB, enhancing the user experience.

• Components for All-in-One Sweeper Robots: Components integrated with automatic cleaning and drying functions are made of moisture and heat-resistant materials, ensuring long-term stable operation.