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Thin wall Product development |
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Client: A consumer durable manufacturer from Shenzhen
Challenge:
To create telephone outer casing with a wall |
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thickness of 0.85 mm.
Method: Demands to create smaller, lighter parts have made thin-wall molding one of the most sought after capabilities. Apart from the selection of the optimum raw material, thinner wall sections bring changes in processing requirements: higher pressures and speeds, faster cooling times, and modifications to part-ejection and gating arrangements. These process changes have in turn prompted new considerations in mold, machinery, and part design... |
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Gas Assisted Injection Molding |
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Client: An Injection molding company from Bangkok.
Challenge: To develop a large automotive part with light weight, and |
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higher strength without the use of conventional ribs.
Method: Espoir team redesigned the part with optimum rib to wall thickness ratio and did the flow analysis. In operation, the mold is partially filled and then gas is introduced into the melt stream (near the point of injection) at a very high pressure. The gas pressure pushes the plastic into the tool to pack it out, and a hollow cross-section is created in the part... |
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Nylon Alloys |
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Client: An automotive accessories manufacturer from Shanghai.
Challenge: Designing a process specifically for this product so that it is possible to eliminate primer on the plastic part |
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Method: Espoir team decided to look for all options right from the material selection, filling of the part for a better surface finish to the construction of the mold and the surface finish achievable in the plastic mold quality pre-hardened steel. One objective was to reduce the cycle time and to reduce the cost of painting and to get a better surface finish..... |
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Twin shot molding |
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Client: An injection molder of large plastic parts from Mumbai.
Challenge: Reduce the cost of the large bumpers for automotive applicatio ns by a break through |
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method.
Method: Espoir team applied their critical mind and applied the lateral thinking. We devised a plan to make use of the rejections from the same injection molding shop to fill the thicker areas of this bumper mold. Using this technology, we can have a recycled / cheap material as a core and the performance material as the skin... |
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In Mold Decoration |
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Client: A remote control supplier for televisions.
Challenge: To develop an automated system for the surface decoration.
Method: Espoir team redesigned the part and |
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the mold to take care of the precision requirements related to the injection process, cooling process and the entry of the decorative film. Lamination of this film with graphics on to 3D molded parts in one step molding. The aesthetics are kept intact by printing the Graphics subsurface... |
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Cubic Printing |
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Client: An auto-component plastics supplier from Noida.
Challenge: To develop a wood like finish on plastic parts using Cubic printing technology.
Method: Espoir team |
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partnered with this auto-component plastics supplier for the development of auto interior products as per the principles of concurrent engineering. Espoir team decided the way in which the parts are split based on the convenience of injection molding, system integration requirements and the basic requirements for the cubic printing... |
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