S136H · 1+1 cavities
An edge gate and direct ejection were selected for the approved part and mould layout.
Project specification
Verified part, tooling and inspection details
Part dimensions180 × 140 × 10 mm
Minimum wall thickness1.4 mm
Critical dimensional tolerance±0.05 mm
MaterialPC
Mould steel / cavities / gating / ejectionS136H · 1+1 cavities · edge gate · direct ejection
Machining equipmentCNC · slow wire EDM · mirror EDM · grinding · milling
Inspection equipmentCMM · 2.5D vision measuring system · profile projector · gauge blocks
Production reference3,000 parts in approximately 3 days after approval
Final quality result96% good part rate
Semiconductor charging equipment case
Thin Wall Charging Station Housing
A production mould for a thin PC housing used in semiconductor charging equipment. Insert moulded nuts and thin sections made filling, local strength and assembly interfaces the key engineering topics.
ApplicationSemiconductor charging
MaterialPC
Tool steelS136H
Tooling1+1 cavities
Delivery30 days
01 · Customer need and engineering challenge
A 30 day tooling program for a thin wall housing with insert moulded nuts
The customer required the mould to be delivered within 30 days for a PC charging station housing. The product was thin and included insert moulded nuts, so the project review focused on filling balance, local wall strength, nut position and reliable release.
01
Thin wall fillingThin sections increased the risk of short shots during the first mould trials.
02
Insert moulded nutsNut positions needed sufficient surrounding thickness without visible nut marks.
03
Assembly interfaceThe finished housing had to assemble successfully into the customer's product.
02 · Tooling approach
DFM led tooling with a focused trial correction
Controlled mould construction
CNC, slow wire EDM, mirror EDM, grinding and milling were used for the mould components.
Two trial rounds
Short shots and nut marks were identified during two trials. The nut boss area was thickened to improve filling and local strength.
03 · Result and customer value
Delivered in 30 days and ready for customer assembly
The mould was delivered within the 30 day target. After two trial rounds and the nut boss adjustment, the project reached a final good part rate of 96% and the finished parts were accepted for assembly into the customer's product.
Customer business value
Supported a smooth assembly process and enabled the finished charging equipment product to move into the market.
Supported a smooth assembly process and enabled the finished charging equipment product to move into the market.
30 daysMould delivery
2Trial rounds
96%Good part rate
A clear path from drawing to production
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