Material Selection and Comparative Analysis
ABS Material Characteristics
- Mechanical Strength: High impact resistance
- Processing Performance: Good molding fluidity
- Heat Resistance: Long-term working temperature about 80-85℃
- Cost Advantage: Relatively low price
- Application Scenarios: General consumer-grade chargers
PC Material Characteristics
- Heat Resistance: Long-term working temperature up to 130-135℃
- Flame Retardancy: UL94 V0 flame retardant standard
- Mechanical Properties: High strength and rigidity
- Transparency: Can produce transparent shells
- Application Scenarios: High-end fast charging chargers
PC/ABS Alloy Material
- Comprehensive Performance: Combines ABS toughness and PC heat resistance
- Working Temperature: 100-110℃
- Flame Retardant Grade: Up to UL94 5VA
- Cost Control: Optimal cost-performance ratio
- Application Scenarios: Mid-to-high-end charger market
Material Selection Recommendations
- General Applications: ABS material (cost priority)
- Fast Charging Products: PC material (safety priority)
- Balanced Choice: PC/ABS alloy (performance and cost balance)
Injection Molding Technology Details
Key Mold Design Technologies
Cavity Layout Design
- Multi-cavity Mold: Usually adopts 2-cavity or 4-cavity design
- Symmetrical Layout: Balanced injection pressure distribution
- Spacing Control: Cavity distance ≥20mm to ensure molding quality
Gating System Optimization
- Hot Runner Technology: Reduces waste by 15-20%
- Pin Gate Design: Gate diameter 0.8-1.2mm
- Position Optimization: Non-visible surface feeding to avoid affecting appearance
Cooling System Design
- Conformal Cooling: Water channels distributed along cavity contour
- Temperature Control: 25-30℃ cooling water
- Efficiency Improvement: Shortens cooling cycle by 20-30%
Injection Molding Process Parameters
Temperature Control
- Barrel Temperature: Rear section 160-170℃, middle section 170-180℃, front section 180-190℃
- Nozzle Temperature: 170-180℃
- Mold Temperature: 90-120℃
Pressure Control
- Injection Pressure: 80-130MPa
- Holding Pressure: 60-80% of injection pressure
- Back Pressure Control: 2-5MPa
Time Control
- Injection Time: 20-90 seconds
- Cooling Time: 20-60 seconds
- Total Cycle: Approximately 60 seconds
Customization Process Analysis
Step 1: Requirements Analysis and Confirmation
- Product Positioning: Determine target market and application scenarios
- Functional Requirements: Insulation performance, flame retardant grade, appearance requirements
- Technical Specifications: Dimensional accuracy, surface roughness, fitting requirements
- Cost Budget: Material selection, production volume, processing complexity
Step 2: Design and Development Phase
- 3D Modeling: 3D design using CAD software
- Structural Optimization: Consider mold manufacturing and injection molding processes
- DFM Analysis: Design for manufacturability evaluation
- Sample Confirmation: 3D printed sample verification of design plan
Step 3: Mold Manufacturing
- Mold Design: Cavity layout, gating system, cooling system
- CNC Machining: Precision cutting with dimensional accuracy ±0.005mm
- Surface Treatment: Polishing, chrome plating to enhance mold release
- Trial Run Debugging: Optimize injection parameters to ensure molding quality
Step 4: Mass Production
- Production Preparation: Raw material preparation, equipment debugging
- Quality Monitoring: First article inspection, process control, finished product inspection
- Packaging and Transportation: Protective packaging, logistics distribution
- After-sales Service: Quality tracking, technical support
Manufacturing Process Flow
Raw Material Preparation
- Material Selection: Choose appropriate plastic according to product requirements
- Drying Treatment: Preheating at 80-100℃ for 3-5 hours
- Quality Inspection: Check material purity and performance indicators
- Storage Management: Moisture-proof, dust-proof, temperature control
Injection Molding
- Equipment Debugging: Set temperature, pressure, time parameters
- Mold Installation: Precise installation and positioning of molds
- Trial Production: Adjust process parameters to optimize molding effect
- Mass Production: Stable operation, quality monitoring
Post-processing Technology
- Deburring: Remove gates and flash
- Surface Treatment: Sanding, polishing, spraying
- Assembly Testing: Fit testing with internal components
- Packaging and Storage: Product packaging and quality inspection
Quality Control System
- Dimensional Inspection: Coordinate measuring machine for accuracy testing
- Performance Testing: Heat resistance, flame retardancy, insulation testing
- Appearance Inspection: Surface quality and color consistency
- Reliability Testing: Drop testing, life testing
Performance Comparison and Safety Certification
Key Performance Indicator Comparison
|
Performance Indicator
|
ABS Material
|
PC Material
|
PC/ABS Alloy
|
|
Heat Resistance
|
80-85℃
|
130-135℃
|
100-110℃
|
|
Flame Retardant Grade
|
UL94 HB
|
UL94 V0
|
UL94 5VA
|
|
Impact Strength
|
High
|
Very High
|
Very High
|
|
Processing Performance
|
Good
|
Average
|
Good
|
|
Cost Index
|
Low
|
High
|
Medium
|
Safety Certification Requirements
- UL Certification: US safety certification standard
- CE Certification: EU safety certification standard
- RoHS Certification: Environmental material certification
- CCC Certification: China Compulsory Certification
- FCC Certification: Electromagnetic compatibility certification
Safety Design Key Points
- Insulation Distance: Shell to high-voltage points ≥13mm
- Flame Retardant Requirements: Meet UL94 V0 standard
- Heat Resistance Design: Consider long-term working temperature
- Structural Strength: Drop and impact resistance
Xiamen Goldcattle Service Advantages
Xiamen Goldcattle Injection Molding Service Advantages
Company Strength Display
Technical Strength
- 26 Years Experience: Professional injection molding experience
- 100+ Equipment: Advanced processing equipment and testing instruments
- ±0.005mm Precision: Ultra-high precision processing capability
- National High-tech Enterprise: Technical innovation capability certification
Service Advantages
- One-stop Service: Full-process service from design to production
- Quick Response: 7×24 hours technical support
- Quality Assurance: Strict quality control system
- Customized Solutions: Provide personalized solutions according to customer needs
Core Service Content
- Mold Design and Manufacturing: Professional mold design and manufacturing
- Injection Molding: High-precision injection processing service
- Surface Treatment: Spraying, plating, printing and other processes
- Assembly and Testing: Finished product assembly and performance testing
Success Cases
- Smartphone Chargers: Provide shell customization for well-known brands
- Fast Charging Adapters: High-power charger shell solutions
- Wireless Chargers: Wireless charging base shell design
- Car Chargers: Custom shell for in-car environment
Contact Us for Custom Solutions
Why Choose Us?
Professional Team
- 26 years of industry experience
- Professional engineer team
- Advanced technology equipment
- Strict quality control
Customization Advantages
- Personalized design solutions
- Rapid prototyping
- Mass production capacity
- Competitive pricing
Service Commitment
- 7-day quick response
- Quality guarantee
- Technical support
- After-sales service
Contact Us Now for Free Consultation
If you are looking for professional custom phone charger plastic shell services, Xiamen Goldcattle will be your best choice. With rich experience and advanced technology, we can provide you with high-quality, high-efficiency custom solutions.
Please leave a message below, our professional team will contact you within 24 hours to provide you with a free custom solution and quotation!
Contact Information
- Company Name: Xiamen Goldcattle Precision Manufacturing Co., Ltd.
- Website: www.xmgoldcattle.com
This article is prepared by the professional team of Xiamen Goldcattle Precision Manufacturing Co., Ltd., aiming to provide customers with a professional guide to custom phone charger plastic shell services. For any questions or needs, please feel free to contact our professional team.
