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yixun
yixunmold
| Feature | Technical Details | Core Benefits |
|---|---|---|
| Precision Mold Structure | Multi-cavity design (2 cavities standard, customizable), dual-station/dual-parting surface; integrated unscrewing mechanism and hydraulic core-pulling system for gear demolding | Ensures no damage to gear teeth during demolding; enables high-efficiency mass production, reducing per-unit cost |
| Ultra-Precision Tooth Profile Control | Mold cavities machined by high-precision wire EDM and CNC; tooth profile tolerance up to DIN 5-7 (ISO 1328); shrinkage compensation designed based on material characteristics | Finished gears achieve smooth meshing, minimal backlash (<0.02mm), and low-noise transmission |
| Dual-Color Finished Gears | Orange: PA66+GF (glass fiber reinforced nylon); Black: POM (acetal) or flame-retardant PA; one-piece injection molding with integrated reinforcing ribs | Orange gears: high strength and wear resistance for heavy-load scenarios; Black gears: self-lubricating for high-speed, low-noise operation |
| Durable Mold Construction | Cavity/core: H13/SKD61 hardened steel (heat-treated to HRC 52-56); Mold base: S50C; mirror polishing (Ra ≤ 0.2μm) for cavity surfaces | Mold service life up to 500,000+ cycles; resistant to high pressure and high temperature during injection molding |
| One-Stop Solution | Integrated services: mold design, precision machining, mold testing, finished gear injection, and quality inspection | Simplifies supply chain, shortens lead time, and ensures consistent quality between mold and finished products |
| Parameter | Mold Specifications | Finished Gear Specifications | Custom Options |
|---|---|---|---|
| Type | Multi-cavity injection mold for spur gears | Plastic spur gears (internal/external teeth) | Helical/bevel/worm gears; 2K injection mold |
| Cavity Count | 2 cavities (standard) | Matching mold cavity count | 4-16 cavities for high-volume production |
| Material | Cavity/core: H13/SKD61; Mold base: S50C | Orange: PA66+GF; Black: POM/flame-retardant PA | PEEK, PPS, medical-grade plastics |
| Tolerance | Cavity tolerance: ±0.005mm | Tooth profile: DIN 5-7; Overall dimension: ±0.02mm | Custom tolerance for ultra-precision applications |
| Surface Finish | Mirror polishing (Ra ≤ 0.2μm) | Matte/textured finish; deburred tooth edges | Gloss finish, laser marking, custom textures |
| Cycle Time | 30-45 seconds per cycle | Consistent with mold cycle time | Optimized to 25-35 seconds for high-volume runs |
| Certifications | ISO 9001, RoHS | ISO 9001, RoHS, REACH | FDA, USP Class VI (for medical applications) |
Automotive Industry: Window regulators, seat adjustment motors, wiper motor reduction gears, HVAC blower components, and EV auxiliary powertrain parts
Power Tools: Transmission gears for electric drills, angle grinders, and cordless screwdrivers
Smart Home & Consumer Electronics: Drive gears for robot vacuums, electric curtains, camera lens adjustment mechanisms, and small household appliances
Industrial Automation: Small servo motor gears, reducer core components, conveyor system transmission parts, and pick-and-place robot gears
Medical Devices: Precision gears for diagnostic equipment, infusion pumps, and lab automation systems (available in medical-grade materials)
Mold Design & Engineering: 3D CAD/CAM design with mold flow analysis (CAE) to optimize cavity layout, cooling system, and demolding mechanism; gear tooth profile simulation to ensure meshing performance.
Precision Machining: High-speed CNC milling, wire EDM, and EDM sinking for mold cavity/core machining; precision grinding and polishing to achieve mirror surface finish and tight tolerances.
Injection Molding: Servo-driven injection molding machines with closed-loop control for consistent material dosing and pressure; automated feeding and ejection systems to minimize human error.
Mold: CMM (Coordinate Measuring Machine) inspection for cavity precision and dimensional accuracy.
Finished Gears: Gear measuring machine to verify tooth profile, pitch, and backlash; tensile testing and wear testing to ensure material performance.
Traceability: Full batch traceability for materials, mold production, and finished gear injection, providing complete quality documentation for clients.
Mold Customization: Cavity count adjustment (2-16 cavities), gear type customization (spur, helical, bevel), unscrewing/core-pulling mechanism optimization, and mold material upgrade.
Finished Gear Customization: Gear size (module 0.2-3.0), tooth count, material selection, color customization, surface finish, and integrated structural design (reinforcing ribs, mounting holes).
Process Customization: Insert molding (metal hubs/shafts), overmolding for hybrid components, and post-processing services (laser marking, precision deburring).
Precision Expertise: Decades of experience in designing and manufacturing precision gear molds, with tooth profile accuracy up to DIN 5 level, ensuring smooth and efficient power transmission.
One-Stop Service: From mold design, machining, and testing to finished gear injection, we simplify your supply chain, reduce communication costs, and shorten lead times.
Cost Efficiency: Multi-cavity mold design and automated production lines reduce per-unit costs, while high-quality materials and craftsmanship extend product service life, lowering long-term maintenance costs.
Global Compliance: Our products meet ISO 9001, RoHS, suitable for global markets, including Europe, America, and Southeast Asia.
Full-Scale Support: Our professional engineering team provides 24/7 technical support, from initial design consultation to after-sales mold maintenance and spare parts supply.
| Feature | Technical Details | Core Benefits |
|---|---|---|
| Precision Mold Structure | Multi-cavity design (2 cavities standard, customizable), dual-station/dual-parting surface; integrated unscrewing mechanism and hydraulic core-pulling system for gear demolding | Ensures no damage to gear teeth during demolding; enables high-efficiency mass production, reducing per-unit cost |
| Ultra-Precision Tooth Profile Control | Mold cavities machined by high-precision wire EDM and CNC; tooth profile tolerance up to DIN 5-7 (ISO 1328); shrinkage compensation designed based on material characteristics | Finished gears achieve smooth meshing, minimal backlash (<0.02mm), and low-noise transmission |
| Dual-Color Finished Gears | Orange: PA66+GF (glass fiber reinforced nylon); Black: POM (acetal) or flame-retardant PA; one-piece injection molding with integrated reinforcing ribs | Orange gears: high strength and wear resistance for heavy-load scenarios; Black gears: self-lubricating for high-speed, low-noise operation |
| Durable Mold Construction | Cavity/core: H13/SKD61 hardened steel (heat-treated to HRC 52-56); Mold base: S50C; mirror polishing (Ra ≤ 0.2μm) for cavity surfaces | Mold service life up to 500,000+ cycles; resistant to high pressure and high temperature during injection molding |
| One-Stop Solution | Integrated services: mold design, precision machining, mold testing, finished gear injection, and quality inspection | Simplifies supply chain, shortens lead time, and ensures consistent quality between mold and finished products |
| Parameter | Mold Specifications | Finished Gear Specifications | Custom Options |
|---|---|---|---|
| Type | Multi-cavity injection mold for spur gears | Plastic spur gears (internal/external teeth) | Helical/bevel/worm gears; 2K injection mold |
| Cavity Count | 2 cavities (standard) | Matching mold cavity count | 4-16 cavities for high-volume production |
| Material | Cavity/core: H13/SKD61; Mold base: S50C | Orange: PA66+GF; Black: POM/flame-retardant PA | PEEK, PPS, medical-grade plastics |
| Tolerance | Cavity tolerance: ±0.005mm | Tooth profile: DIN 5-7; Overall dimension: ±0.02mm | Custom tolerance for ultra-precision applications |
| Surface Finish | Mirror polishing (Ra ≤ 0.2μm) | Matte/textured finish; deburred tooth edges | Gloss finish, laser marking, custom textures |
| Cycle Time | 30-45 seconds per cycle | Consistent with mold cycle time | Optimized to 25-35 seconds for high-volume runs |
| Certifications | ISO 9001, RoHS | ISO 9001, RoHS, REACH | FDA, USP Class VI (for medical applications) |
Automotive Industry: Window regulators, seat adjustment motors, wiper motor reduction gears, HVAC blower components, and EV auxiliary powertrain parts
Power Tools: Transmission gears for electric drills, angle grinders, and cordless screwdrivers
Smart Home & Consumer Electronics: Drive gears for robot vacuums, electric curtains, camera lens adjustment mechanisms, and small household appliances
Industrial Automation: Small servo motor gears, reducer core components, conveyor system transmission parts, and pick-and-place robot gears
Medical Devices: Precision gears for diagnostic equipment, infusion pumps, and lab automation systems (available in medical-grade materials)
Mold Design & Engineering: 3D CAD/CAM design with mold flow analysis (CAE) to optimize cavity layout, cooling system, and demolding mechanism; gear tooth profile simulation to ensure meshing performance.
Precision Machining: High-speed CNC milling, wire EDM, and EDM sinking for mold cavity/core machining; precision grinding and polishing to achieve mirror surface finish and tight tolerances.
Injection Molding: Servo-driven injection molding machines with closed-loop control for consistent material dosing and pressure; automated feeding and ejection systems to minimize human error.
Mold: CMM (Coordinate Measuring Machine) inspection for cavity precision and dimensional accuracy.
Finished Gears: Gear measuring machine to verify tooth profile, pitch, and backlash; tensile testing and wear testing to ensure material performance.
Traceability: Full batch traceability for materials, mold production, and finished gear injection, providing complete quality documentation for clients.
Mold Customization: Cavity count adjustment (2-16 cavities), gear type customization (spur, helical, bevel), unscrewing/core-pulling mechanism optimization, and mold material upgrade.
Finished Gear Customization: Gear size (module 0.2-3.0), tooth count, material selection, color customization, surface finish, and integrated structural design (reinforcing ribs, mounting holes).
Process Customization: Insert molding (metal hubs/shafts), overmolding for hybrid components, and post-processing services (laser marking, precision deburring).
Precision Expertise: Decades of experience in designing and manufacturing precision gear molds, with tooth profile accuracy up to DIN 5 level, ensuring smooth and efficient power transmission.
One-Stop Service: From mold design, machining, and testing to finished gear injection, we simplify your supply chain, reduce communication costs, and shorten lead times.
Cost Efficiency: Multi-cavity mold design and automated production lines reduce per-unit costs, while high-quality materials and craftsmanship extend product service life, lowering long-term maintenance costs.
Global Compliance: Our products meet ISO 9001, RoHS, suitable for global markets, including Europe, America, and Southeast Asia.
Full-Scale Support: Our professional engineering team provides 24/7 technical support, from initial design consultation to after-sales mold maintenance and spare parts supply.
