Product core demand and technology positioning. This solution for breast pump liquid silicone valve high-precision moulding needs, the use of 1 out of 4 needle valve cold runner breast pump mould structure, die core selection of S136 mould steel (heat treatment to HRC48-52), die frame using P20 steel, combined with horizontal liquid silicone machine (LSR) and robotic automation system, to achieve the production of high-precision, high-efficiency, low human intervention in the whole process of the production goals, to meet the medical grade silicone products for dimensional tolerance (±0.02mm), no surface defects (Ra≤0.2μm).
Product core demand and technology positioning
Mold Design and Key Technologies
1.Mold Core and Parting Surface Design
The S136 core is treated for durability and corrosion resistance, while the cavity is designed with 3D scanning and compensates for silicone shrinkage (1.5%-2.0%). Parting surfaces are ground to achieve ≤0.005mm parallelism, improving mold release.
2.Needle Valve Cold Runner System
A hot runner needle valve system with four independent valves makes sure that filling multiple cavities happens at the same time without leaving any glue residue. Computer simulations of the mould help to design the runner layout so that pressure (ΔP<5%) and temperature (≤3℃) are balanced, which stops problems with the flow.
3.Automated demoulding and production integration
- The ejector system adopts servo motor to drive the ejector plate, together with the robotic clamping positioning accuracy of ±0.1mm, to achieve full automation of demoulding - picking up - setting up, reducing the rate of manual intervention by 80%.
- Moulds are equipped with RFID chips to collect real-time data of breast pump mould times, temperature and pressure, and link with MES system to achieve digital monitoring and tracing of the production process.
Precision machining and assembly process
1. Mould core processing
- Cavity using five-axis linkage precision machining centre (accuracy ± 0.003mm), rough machining after deep cold treatment to eliminate residual stress, finishing surface mirror polishing to Ra0.05μm.
2. Mould frame and assembly
- P20 mould frame is processed by large-scale gantry milling, guide pillar/guide sleeve matching clearance ≤ 0.005mm, parallelism of breast pump mould frame ≤ 0.01mm/300mm.
Making sure products are good
1. Making the trial breast pump mould better
- Experimenting to find the best way to do things (DOE): injection pressure 80-120MPa, mould temperature 160-180°C, vulcanisation time 25-35 seconds.
2. Controlling mass production*
- A system that checks products as they go along automatically finds problems like lack of glue, burrs, etc., defective rate <0.3%.
- SPC critical size sampling inspection (CpK≥1.67) every 500 moulds, mould life≥500,000 moulds.
FAQ
Q: What's your after-sale service?
A: One year free warranty and lifelong maintenance.Provide professional and efficient product consulting and repair service to customers.
Q: What's your Pre-sales services
A: 1.Drawings/samples /requirements 2.Scheme evaluation and design
Q: How can we get a quote?
A: Contact us with specification: such as
A: For filling machine: quantity, filling material, filling range, filling speed, etc.
B: For capping machine: quantity, diameter and height of cap with pictures.
C: For labeling machine:quantity, type of labels, size of labels, diameter and height of your containers. It'd better if you can provide us some pictures.
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