S136H · 1+1 cavities
An edge gate and direct ejection were planned around the cover geometry and internal bosses.
Project specification
Verified part, tooling and inspection details
Part dimensions100 × 80 × 60 mm
Minimum wall thickness0.8 mm
Critical dimensional tolerance±0.05 mm
MaterialPC/ABS
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 4 days after approval
Final quality result98% good part rate
Smart home injection moulding case
Smart Switch Cover
A PC/ABS cover for a smart home control product. Multiple side openings, small internal holes and long bosses required coordinated release, venting and surface finishing.
ApplicationSmart home controls
MaterialPC/ABS
Tool steelS136H
Tooling1+1 cavities
Delivery30 days
01 · Customer need and engineering challenge
Engineering a smart switch cover with complex openings and long bosses
The customer required a PC/ABS smart switch cover within a 30 day mould delivery target. The part included multiple side openings, small internal holes and long slender bosses, making release, venting, filling and polishing important to the final appearance and function.
01
Multiple side openingsSide features required coordinated release planning in the mould structure.
02
Small internal holesRestricted air evacuation increased the risk of short shots and trapped air.
03
Long bossesLong internal columns increased sticking risk during ejection.
02 · Tooling approach
DFM led tooling with release and venting improvements
Precision detail work
CNC, slow wire EDM, mirror EDM, grinding and milling supported the mould construction and surface detail.
Three trial rounds
Sticking, short shots and weld lines were addressed by increasing draft, enlarging venting and polishing the relevant mould areas.
03 · Result and customer value
Delivered in 30 days and ready for the customer's product launch
The mould was delivered within 30 days. Three trial rounds stabilized release and filling, reaching a final good part rate of 98%. The finished cover assembled successfully into the customer's smart home product.
Customer business value
Supported an on time product launch, reduced schedule risk and provided a stable assembly ready component.
Supported an on time product launch, reduced schedule risk and provided a stable assembly ready component.
30 daysMould delivery
3Trial rounds
98%Good part rate
A clear path from drawing to production
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