| Quantity: | |
|---|---|
25103
YIXUN mold
8480419090
| Parameter | Full Details |
|---|---|
| Mold Name | 1×1 Cavity Overmold Mold for PC Makrolon 2407 + TPE/TPU Shore A 65 |
| Product ID | 25410003140 (TPE/TPU Part) + 25410003140 Additional Part (PC Part) |
| Cavity Layout | 1×1 per material (two separate molds or a two-shot overmold configuration) |
| Materials | 1. Rigid Part: PC Makrolon 2407 (Bayer Covestro, industrial grade, impact-modified)2. Soft Overmold: TPE or TPU, Shore A 65 hardness |
| Mold Steel | 1.2344 (40CrMnMo7) Hot Work Tool Steel, hardened to HRC48–50 (cavity & core) |
| Surface Finish | VDI 30 texture (industrial-grade matte finish, uniform across both materials) |
| Runner System | Large Sprue Cold Runner (balanced flow for both rigid and soft materials) |
| Mold Life | ≥ 1,000,000 cycles (under proper maintenance) |
| Process Type | Sequential overmolding (PC part molded first, then TPE/TPU overmolded onto the substrate) |
Material Choice: 1.2344 is a premium hot work tool steel, selected for its exceptional toughness, heat resistance, and wear resistance—critical for molding both rigid PC and soft TPE/TPU materials. Heat-treated to HRC48–50, it withstands high injection pressures, thermal cycling, and the abrasive nature of filled/modified polymers, ensuring long mold life and dimensional stability.
Structure: The mold features a robust, industrial-grade base with precision-machined cavities and cores. The 1×1 cavity layout allows for focused control over each part’s critical dimensions, ideal for complex geometries like the angled, ribbed PC component and flat, multi-hole TPE/TPU plate.
The mold is finished to VDI 30 (Ra ≈ 2.5–3.0 μm), a standard industrial texture that delivers a consistent matte appearance. This finish is chosen for two key reasons:
It provides excellent grip and anti-slip properties for the TPE/TPU part, enhancing its functional performance.
It hides minor surface imperfections (e.g., flow lines, sink marks) common in PC and TPE molding, while ensuring uniform texture across both materials for a cohesive assembly appearance.
The large sprue cold runner system is optimized for both materials:
For PC Makrolon 2407: The large sprue reduces pressure drop, ensuring complete filling of the thick, complex PC component without short shots or cold flow defects.
For TPE/TPU Shore A 65: The wide, balanced runner minimizes shear stress on the soft polymer, preventing material degradation and ensuring uniform flow into the mold cavity.
The cold runner design is cost-effective and easy to maintain, making it ideal for industrial production where downtime must be minimized.
Material Properties: Makrolon 2407 is an impact-modified polycarbonate with high toughness, good UV resistance, and low-temperature performance, making it ideal for industrial structural components.
Molding Considerations: The mold is designed to handle PC’s high melt temperature (~280–320°C) and require high clamping force. The 1×1 layout allows for precise control over cooling rates, minimizing warpage in the thick, angled geometry.
Material Properties: Shore A 65 TPE/TPU balances softness and durability, providing impact absorption, vibration damping, and a non-slip surface. It is engineered to bond securely to the PC substrate during overmolding.
Molding Considerations: The mold features precise alignment features to ensure the soft material flows only onto the designated PC surface, eliminating flash or material migration. The large sprue design prevents shear-induced degradation of the TPE/TPU, preserving its Shore A 65 hardness and elasticity.
Heavy equipment protective covers
Vibration-damping components for machinery
Industrial tool grips and handles
Automotive interior/exterior trim parts
Electronic device housings with soft-touch surfaces
Cavity layout expansion (1×2, 1×4 multi-cavity for higher volume production)
Gate system upgrades (hot runner/valve gate for zero scrap production)
Surface finish modifications (custom VDI/SPI textures, polished or textured regions)
Mold steel upgrades (corrosion-resistant grades for medical/cleanroom use)
Material-specific adjustments (compatibility with other PC grades or TPE/TPU hardnesses)
Secondary process integration (e.g., insert molding, assembly fixtures)
Optimized for Overmolding: The mold’s design ensures perfect alignment and bonding between the PC and TPE/TPU parts, eliminating assembly errors.
Long-Lasting Performance: 1.2344 steel with HRC48–50 hardness delivers millions of cycles of consistent production, reducing replacement costs.
Versatile Compatibility: Works with two distinct materials, making it ideal for multi-component industrial assemblies.
Cost-Effective Production: The cold runner system reduces upfront costs and maintenance, while the 1×1 layout ensures precise control over each part’s quality.
