Electronic sensor housings demand a balanced combination of optical clarity, structural toughness and precise dimensional consistency. Today we share our completed injection mold project for the BA Alpha Box, a three-piece transparent MABS enclosure widely used for compact electronic modules and sensor assemblies.
The BA Alpha Box consists of three separate components: Top cover, Middle cover and Lower frame. All parts are designed to snap together, forming a complete protective housing for internal circuit boards. Transparent material allows engineers to visually inspect components without disassembling the unit, a critical advantage for sensor and low-voltage electronic applications.
We selected MABS as the production material for this project. Modified ABS delivers great light transmission while maintaining higher impact resistance than standard transparent ABS. The material shrinkage rate is set at 0.5%, which we fully considered during mold design to avoid warpage, uneven gaps and assembly failures after molding.
Mold Technical Highlights
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Multi-cavity Layout
We adopted a 2+1+1+1+1+1 multi-cavity configuration, enabling simultaneous molding of all 3 housing components in one production cycle. This layout optimizes cycle efficiency and balances output ratios for assembly.
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Submarine Gate (Sub Gate) / Large Sprue Design
The mold uses large sprue submarine gating. The gate automatically separates from finished parts during ejection, leaving minimal visible marks on the transparent surface. This eliminates manual gate trimming and protects the high-gloss appearance of clear plastic products.
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Strategic Mold Steel Selection
Cavity Steel (Front Mold): NAK80
NAK80 offers excellent polishability, allowing us to achieve high-gloss mirror finish required for transparent MABS to reduce haze and improve light transmission.
Core Steel (Rear Mold): Pre-hardened steel HRC 37–43
The non-visible inner core adopts cost-effective pre-hardened steel, meeting structural requirements while controlling overall mold investment.
Full Mold Polishing Standard
Both cavity and core surfaces receive professional polishing treatment. Proper surface finish helps avoid flow marks, cloudiness and visible molding defects common on transparent plastic parts.
![MABS Sensor Housing Injection Mold]( "MABS Sensor Housing Injection Mold")
Molding Challenges & Solutions
Transparent MABS is sensitive to moisture and unstable injection parameters. To prevent silver streaks, air bubbles and flow lines:
Strict raw material drying procedure before production
Controlled mold temperature between 60℃ – 80℃
Optimized injection speed and holding pressure to stabilize melt flow
Application & Customization
This transparent enclosure serves small sensors, Bluetooth modules and compact electronic assemblies. We provide fully customized injection mold service: custom dimensions, material options (PC, PMMA, MABS), surface texture, gate type and multi-cavity layout according to client drawings or samples.
If you are sourcing reliable injection mold manufacturer for transparent plastic electronic housings, feel free to contact us for mold quotation and technical support.
