| Quantity: | |
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Yixun 241122
Yixun
3926909090
1.The manufacturing principle of plastic gears:
Mainly using the injection molding process, high-temperature molten plastic material is injected into the mold. After cooling in the mold, the plastic will form a gear with a specific shape. The cost of making plastic gears is lower than that of metal gears, and colors and other special additives can be added to meet different customer needs.
2.Application scope of plastic gears：
Plastic gears have a wide range of applications, mainly covering the fields of home appliances, medical equipment, automobiles, robots and other mechanical equipment. At the same time, in some manufacturing fields, the emergence of plastic gears will further improve the efficiency and quality of the entire industry. Although the load-bearing capacity of plastic gears is relatively limited, its lightweight and cost advantages will continue to expand its application trend in certain fields.
We specialize in the design and manufacturing of high-precision injection molds for plastic and powder metal gears. Serving industries from automotive to robotics, medical devices to consumer electronics, our molds produce gears that meet the most demanding standards for noise reduction, transmission efficiency, and long-term reliability.
From miniature gears under 1mm to large-diameter transmission components, we transform your gear design into a manufacturable reality with unmatched precision.
| Capability | Technical Specification & Detail | Benefit to You |
|---|---|---|
| Ultra-High Precision Machining | • Tolerances: Achieve gear tooth profile tolerances within ±0.005mm (5µm). • Equipment: 5-axis CNC, Swiss-type CNC lathes, Jig Grinders, Wire EDMs. • Profile Control: Dedicated gear hobbing/cutting or precision EDM for involute profiles. | Ensures gear meshing smoothness, minimizes backlash and noise, and guarantees consistent performance across millions of cycles. |
| Advanced Mold Flow & Cooling Analysis | • Pre-Analysis: Full Moldflow® simulation for gear-specific filling, packing, and cooling. • Warpage Prediction: Analysis focused on minimizing circular runout and tooth distortion. | Optimizes mold design upfront, prevents shrinkage defects on teeth, reduces trial cycles, and ensures dimensional stability. |
| Specialized Surface Treatments & Coatings | • Options: Nickel-PTFE, DLC (Diamond-Like Carbon), TiN, Chromium plating, specialized nitriding. • Application: Applied to core/cavity, ejector pins, and sliders. | Dramatically extends mold life, reduces wear on critical tooth profiles, improves release, and minimizes maintenance downtime. |
| Micro-Gear & Miniature Molding Expertise | • Scale: Molds for gears with module as fine as 0.1 and OD under 2mm. • Ejection Technology: Micro-pins, sleeve ejectors, or air-assisted ejection systems. | Enables miniaturization of devices (medical, micro-drives, optics) with flawless small-gear production. |
| Integrated Automated De-Gating Solutions | • Design: In-mold shear gates, hot runner systems, or automatic degating fixtures. • Focus: Protecting delicate gear teeth from damage during separation. | Protects critical gear geometry, reduces post-processing, lowers labor cost, and improves overall part quality. |
Automotive: Window regulators, seat adjusters, wiper systems, transmission actuators, pump gears (oil, water, fuel).
Medical & Dental: Surgical hand tool drives, pump gears in diagnostic devices, dental drill transmissions, insulin pump mechanisms.
Consumer Electronics: Printer/Scanner gear trains, camera lens drive systems, smart home actuator gears, precision toy mechanisms.
Industrial & Robotics: Encoder gears, servo motor components, robotic joint drives, conveyor system components, meter gears.
Home Appliances: Gearboxes for mixers, blender drives, timer mechanisms, actuator gears for smart appliances.
Gear-Centric DFM (Design for Manufacturing): We review your gear design not just as a part, but as a molded component. We advise on optimal draft angles for tooth flanks, root fillet radii, gate locations relative to the tooth profile, and wall thickness uniformity to ensure pack-out without sink marks.
Rigidity-First Mold Structure: Gear molds require exceptional stiffness to withstand high injection pressures without deflection. We use high-grade steels (e.g., Stavax, H13) and design with massive support plates and precise guiding systems to maintain alignment.
Cooling is Critical: Uneven cooling causes warpage, directly impacting gear runout. We design conformal cooling channels wherever possible, especially around the gear core, to ensure uniform heat extraction and stable tooth geometry.
Ejection with Zero Damage: Ejecting a part with delicate teeth is a major challenge. We employ carefully placed sleeve ejectors, lifters, or air poppet valves to apply perfectly balanced, gentle force without leaving marks or causing deformation.
Mold Base Steels: P20, H13, S136, Stavax ESR, 1.2344 (for high-wear applications).
Gear Standards Supported: AGMA (American), DIN (German), JIS (Japanese), ISO standards.
Quality Assurance: Full CMM inspection of first-article molds, gear profile projector checks, and sample gear testing for noise, runout, and strength.
Certifications: ISO 9001:2015 quality management system. Compliant with IATF 16949 standards for automotive projects.
Consultation & Feasibility: Review of 2D/3D gear drawings, material selection, and volume requirements.
Simulation & Quotation: Conduct Moldflow analysis and provide a detailed technical and commercial proposal.
Design Finalization: Collaborative DFM session to finalize mold and gear design.
Precision Manufacturing: Full in-house machining, heat treatment, and finishing.
Assembly & Tryout: Mold assembly, initial sampling on our precision injection presses.
Inspection & Approval: Comprehensive measurement of sample gears and mold refinement if needed.
Delivery & Support: Safe shipment of mold and provision of ongoing technical support.
1.The manufacturing principle of plastic gears:
Mainly using the injection molding process, high-temperature molten plastic material is injected into the mold. After cooling in the mold, the plastic will form a gear with a specific shape. The cost of making plastic gears is lower than that of metal gears, and colors and other special additives can be added to meet different customer needs.
2.Application scope of plastic gears：
Plastic gears have a wide range of applications, mainly covering the fields of home appliances, medical equipment, automobiles, robots and other mechanical equipment. At the same time, in some manufacturing fields, the emergence of plastic gears will further improve the efficiency and quality of the entire industry. Although the load-bearing capacity of plastic gears is relatively limited, its lightweight and cost advantages will continue to expand its application trend in certain fields.
We specialize in the design and manufacturing of high-precision injection molds for plastic and powder metal gears. Serving industries from automotive to robotics, medical devices to consumer electronics, our molds produce gears that meet the most demanding standards for noise reduction, transmission efficiency, and long-term reliability.
From miniature gears under 1mm to large-diameter transmission components, we transform your gear design into a manufacturable reality with unmatched precision.
| Capability | Technical Specification & Detail | Benefit to You |
|---|---|---|
| Ultra-High Precision Machining | • Tolerances: Achieve gear tooth profile tolerances within ±0.005mm (5µm). • Equipment: 5-axis CNC, Swiss-type CNC lathes, Jig Grinders, Wire EDMs. • Profile Control: Dedicated gear hobbing/cutting or precision EDM for involute profiles. | Ensures gear meshing smoothness, minimizes backlash and noise, and guarantees consistent performance across millions of cycles. |
| Advanced Mold Flow & Cooling Analysis | • Pre-Analysis: Full Moldflow® simulation for gear-specific filling, packing, and cooling. • Warpage Prediction: Analysis focused on minimizing circular runout and tooth distortion. | Optimizes mold design upfront, prevents shrinkage defects on teeth, reduces trial cycles, and ensures dimensional stability. |
| Specialized Surface Treatments & Coatings | • Options: Nickel-PTFE, DLC (Diamond-Like Carbon), TiN, Chromium plating, specialized nitriding. • Application: Applied to core/cavity, ejector pins, and sliders. | Dramatically extends mold life, reduces wear on critical tooth profiles, improves release, and minimizes maintenance downtime. |
| Micro-Gear & Miniature Molding Expertise | • Scale: Molds for gears with module as fine as 0.1 and OD under 2mm. • Ejection Technology: Micro-pins, sleeve ejectors, or air-assisted ejection systems. | Enables miniaturization of devices (medical, micro-drives, optics) with flawless small-gear production. |
| Integrated Automated De-Gating Solutions | • Design: In-mold shear gates, hot runner systems, or automatic degating fixtures. • Focus: Protecting delicate gear teeth from damage during separation. | Protects critical gear geometry, reduces post-processing, lowers labor cost, and improves overall part quality. |
Automotive: Window regulators, seat adjusters, wiper systems, transmission actuators, pump gears (oil, water, fuel).
Medical & Dental: Surgical hand tool drives, pump gears in diagnostic devices, dental drill transmissions, insulin pump mechanisms.
Consumer Electronics: Printer/Scanner gear trains, camera lens drive systems, smart home actuator gears, precision toy mechanisms.
Industrial & Robotics: Encoder gears, servo motor components, robotic joint drives, conveyor system components, meter gears.
Home Appliances: Gearboxes for mixers, blender drives, timer mechanisms, actuator gears for smart appliances.
Gear-Centric DFM (Design for Manufacturing): We review your gear design not just as a part, but as a molded component. We advise on optimal draft angles for tooth flanks, root fillet radii, gate locations relative to the tooth profile, and wall thickness uniformity to ensure pack-out without sink marks.
Rigidity-First Mold Structure: Gear molds require exceptional stiffness to withstand high injection pressures without deflection. We use high-grade steels (e.g., Stavax, H13) and design with massive support plates and precise guiding systems to maintain alignment.
Cooling is Critical: Uneven cooling causes warpage, directly impacting gear runout. We design conformal cooling channels wherever possible, especially around the gear core, to ensure uniform heat extraction and stable tooth geometry.
Ejection with Zero Damage: Ejecting a part with delicate teeth is a major challenge. We employ carefully placed sleeve ejectors, lifters, or air poppet valves to apply perfectly balanced, gentle force without leaving marks or causing deformation.
Mold Base Steels: P20, H13, S136, Stavax ESR, 1.2344 (for high-wear applications).
Gear Standards Supported: AGMA (American), DIN (German), JIS (Japanese), ISO standards.
Quality Assurance: Full CMM inspection of first-article molds, gear profile projector checks, and sample gear testing for noise, runout, and strength.
Certifications: ISO 9001:2015 quality management system. Compliant with IATF 16949 standards for automotive projects.
Consultation & Feasibility: Review of 2D/3D gear drawings, material selection, and volume requirements.
Simulation & Quotation: Conduct Moldflow analysis and provide a detailed technical and commercial proposal.
Design Finalization: Collaborative DFM session to finalize mold and gear design.
Precision Manufacturing: Full in-house machining, heat treatment, and finishing.
Assembly & Tryout: Mold assembly, initial sampling on our precision injection presses.
Inspection & Approval: Comprehensive measurement of sample gears and mold refinement if needed.
Delivery & Support: Safe shipment of mold and provision of ongoing technical support.
