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Ultrasonic welding

HOW DOES ULTRASONIC WELDING WORK? Ultrasonic welding is a welding process that uses high-frequency ultrasonic as a heat source and pressure source to obtain instantaneous high temperature and pressure on the surface of the workpiece, so as to soften, melt and fuse the workpiece materials. The working principle of Ultrasonic welding is: during welding, the power source converts the electric energy into ultrasonic energy, and transmits the ultrasonic wave to the workpiece surface through the welding joint, so that the contact between the two workpieces is heated by friction, and dense fusion is carried out under a certain pressure to form a solid welding joint.Ultrasonic welding equipment is usually composed of generator, transducer, welding joint, workpiece and control system. Among them, the generator is the core component that converts electrical energy into ultrasonic energy. The transducer converts the electrical energy of the generator into mechanical vibration, and the welding head transmits the mechanical vibration to the surface of the workpiece through contact for friction heating and pressure dense fusion. The entire process is automatically controlled by the control system. Ultrasonic welding has the advantages of fast welding speed, simple operation, high welding joint strength, environmental friendliness, etc. It is widely used in many industries such as automobile, electronics, pharmacy, medical treatment, food, chemical industry, etc. THE ADVANTAGES OF ULTRASONIC WELDING + Very short process times+ Little or no thermal damage to the component due to cold welding tools+ Low energy requirement for welding and thus high efficiency+ No solvents and additives necessary (pure recycling)+ Constant, reproducible welding results are possible via a wide range of welding parameters+ Different thermoplastic materials can be welded together+ The welding tools do not heat up, so there are no warm-up and cool-down times and the tools can be changed quickly+ No risk of injury from hot machine parts+ Very good integrability into existing systems+ Possibility of intelligent networking and self-control Analysis of Thermoplastic Material in Ultrasonic Welding ABS ABS+PC PE PP PS PMMA NYLON PC ABS Good Good limited ABS+PC Good Good limited PE Good PP Good PS Good PMMA Good NYLON Good PC limited limited limited Good Applications 1.Automobile manufacturing industry: Ultrasonic welding can be used for welding many components in automobile manufacturing industry,Such as instrument panel, seat,lamp,etc 2.Medical device Manufacturing: Ultrasonic welding can be used in medical device manufacturing,such as the sealing of medicine bottles and infusion bottles, mask. 3.Electronic manufacturing industry: Ultrasonic welding can be used to manufacture circuit boards,assembly of electronic equipment and connections on connecting wires 4.Packaging industry: Ultrasonic welding canb e used as packaging matterials in food and pharmaceutical industries. 5.Pipeline manufacturing:Ultrasonic welding can be used to manufacture plastic pipes and metal pipes 6.Textile industry: Ultrasonic welding can be used for sewing and corner treatment of textile materials 7.Air conditioning manufacturing industry: Ultrasonic welding can be used for welding metal elements in air conditioning manufacturing 8.Air purifier manufacturing industry: Ultrasonic welding can be used for the welding of filters in air purifiers FAQS How to make the Ultrasonic welding set ? If you need the set, you need send use the drawing of part and sample. we can do the set follow the drawing and sample. How long will finish a set of Ultrasonic welding ? Approved the drawing, it is only 8-10days

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Sheet Metal Fabrication

What's the Sheet Metal Fabrication? Sheet metal fabrication is the process of turning flat sheet metals, typically 0.15 mm to 10 mm thick, into parts and structures of various shapes. The stock materials for this process are flat metal sheets. Sheet metal is bent, or formed, from two dimensions to three by the use of hardened steel tools and dies which, when forced together with hydraulic power, form the sheet metal to shape and exact angle. Three main ways of Sheet Metal Fabrication >Laser Cutting In laser cutting, a high-density laser beam is directed onto a workpiece to melt, vaporise, or burn through it, effectively cutting the material. Laser cutters are used for cutting, boring, and engraving. There are three types of lasers used in laser cutting; CO2 (carbon dioxide), Nd (neodymium), Nd:YAG (neodymium-doped yttrium aluminium garnet). CO2 lasers have high energy efficiency and high power output ratio, and are used for cutting thin material, engraving, and boring. Nd lasers have high energy but low repetition efficiency. They are used for engraving, boring, and welding. Nd:YAG lasers have a very high power output and can cut thicker materials. However, they are more expensive to operate than CO2. Laser cutters can work with aluminum, steel, copper, stainless steel, and other metals. They are best used for cutting thin workpieces (maximum thickness of 15 mm for aluminium and 6 mm for steel), engraving, and boring >Water-Jet Cutting In water-jet cutting, a nozzle is used to focus a jet of water at very high pressures to cut a workpiece. For relatively soft material like rubber and wood, only water is used. A mixture of water and abrasive granular substances is used to cut harder material such as metals. Water-jet cutting can cut material of various thicknesses. The maximum thickness that can be cut depends on the material. Of all CNC cutting methods, waterjet cutting is the most precise with tolerances between 0.05 mm and 0.1 mm. One of the reasons for its high precision is that unlike plasma and laser counterparts, waterjet cutting does not generate heat hence there is no heat affected zone in the workpiece. Waterjet cutting is very versatile as it is used to cut hard material such as aluminum, steel, copper, stainless steel, and other metal alloys as well as softer materials like polymers, elastomers, wood, and foam. >Plasma Cutting Plasma cutting works by applying heat and energy to a gas to turn it to plasma. A jet of hot plasma is then accelerated using an inert gas or air, out of the cutting nozzle and onto the workpiece. The plasma completes an electrical arc with the workpiece, melting and cutting it. Being an electrical process, plasma cutters only work with electrically conductive material. Plasma cutters can cut through very thick material, up to 300 mm for aluminum and 200 mm for steel, with a tolerance of 0.2 mm. Other materials that are processed using plasma cutters are stainless steel, copper, and other metal alloys. Depending on the complexity of the part to be produced, 2-axis or 3-axis cutters may be used. Although plasma cutters are not as diverse or precise as waterjet and laser cutters, they are the best choice for thick electrically conductive metal parts, as they are faster and more cost-effective for cutting such materials.

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DIE CASTING ALUMINUM MOLD

Die Cast Aluminum Mold is also commonly known as Dies. These molds are used for the mass-production of aluminum parts. Mold making used to be a difficult task before. Thanks to the CNC Machining technology mold making is now faster and more efficient than ever. Aluminum Die casting Mould requires a material that has higher strength and melting temperature than Aluminum. Otherwise, the die will be damaged during the casting process. Usually, steel molds are used for aluminum die casting. High-quality steel is quite costly and hard to machine. So, the die tooling cost is relatively high. Even though the high tooling cost, aluminum die casting toolings provides the best economy and quality for large volume production. Components of Die Casting Mold A Die Cast Mold consists of multiple parts with each serving a specific purpose. The main components in a die casting mold are listed below. >>Cover Die >>Ejector Die>>Ejector Pin>>Runner>>Sprue>>Cavity Insert>>Ejector Plate>>Support Plate etc. Types of Die Cast Mold >Production Dies Production dies are used for large scale production. They are manufactured with high-quality, durable material to ensure longer die life. The initial tooling cost of production die is very high but the cost eventually drops with long term use.>Prototyping DiesThese dies are mainly used for creating prototypes. The tooling process and functionality is the same as that of production dies. But the complex features are simplified and machined with less precision to minimize tooling cost. >Trim Dies After a casting cycle ends, the parts have casting residue such as sprue, runners, risers, flash, etc. Trim dies are used for cutting down excess material from a completed die-casting. It is also used for separating the parts from a casting pattern. Advantages of Aluminum Die Cast Mold Aluminum die cast mould has made the production of aluminum parts a lot easier. Some of the benefits of die casting molds are explained below:>A single mold can produce thousands of parts>Can produce parts with very tight tolerances>Can withstand high temperatures>Can withstand very high pressure>Significantly reduces production cost for large volume production>Can manufacture multiple aluminum parts at one go>Increased rate of cooling and solidification allows faster production>For these multiple advantages, aluminum die-cast mold is being used for boosting aluminum die casting capacity.

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Stamping mold

Stamping mold is the process to exert pressure on the blank so that the blank will undergo steel transformation or separation to produce workpieces with fixed sizes, shapes and properties, stamping process can be divided into separating and forming. Main two types of Stamping Mold: >>Single Engineering Die >>Progressive Die ，Compound Die， Follow Die Single Engineering Die The Die is good for a simple part and the quantity is not large.Normally, it includes the below types: Blanking Cutting Piercing Lancing Trimming Bending Progressive Die Progressive die stamping is a stamping method that utilizes a series of stations installed across a die set. Each station is designed and configured to perform a specific stamping operation on the workpiece and, once it is completed, automatically move it along to the next station. As the workpiece makes its way through the various stations, it progressively takes on the desired shape and size. Main die press components and safety requirements 1. Working components The convex and concave mold is the working part that directly makes the blank shape, therefore, it is the key part of the mold. The convex and concave mold is not only precise but also complex, it should meet the following requirements: (1) It should have sufficient strength and cannot be broken or damaged during the stamping process; (2) Appropriate requirements should be placed on its materials and heat treatment to prevent brittleness due to high hardness. 2. Positioning components Positioning components are parts that determine the installation position of the blank. There are positioning dowel pins, stop pins, guide pins, guide bushings, fixed distance side knives, side presses, etc. When designing positioning parts, you should consider the convenience of operation, there should be no positioning, and the position should be easy to observe. It is best to use forward positioning, outer profile positioning, and guiding pin positioning. 3. Pressing, unloading, and discharging components The blanking parts include a blanking ring, blanking board, etc. The blank holder can exert pressure on the drawn blank, thereby preventing the blank from arching and forming wrinkles under the action of tangential pressure. The function of the holding plate is to prevent the blank from moving and bouncing. The function of the ejector and unloading plate is to facilitate the ejection of parts and the cleaning of waste. They are supported by springs, rubbers, and air cushion pushrods on the equipment, and can move up and down. The ejector pins should have sufficient ejection force and the movement should be limited. The unloading board should minimize the closed area or mill an empty slot in the operating position. The exposed unloading plate shall be surrounded by protective plates to prevent people from reaching out with fingers or foreign objects from entering, and the edges and corners of the exposed surface shall be blunt. 4. Guide components Guide bushings and guide pins are the most widely used guide components. Its function is to ensure that the convex and concave dies have a precise fit clearance during the stamping work. Therefore, the gap between the guide bushing and the guide pin should be smaller than the blanking gap. The guide bushing is set on the lower mold base, and the upper-end surface of the guide pin is at least 5 to 10 mm above the top surface of the upper template at the bottom dead center of the stroke. The guide bushing should be arranged far away from the module and the pressing plate so that the operator’s arm does not need to cross the guide bushing to feed and take materials. 5. Support pillar and mold clamp It includes upper and lower templates, mold handles, fixed plates for convex and concave molds, backing plates, stoppers, mold clamp, etc. The upper and lower templates are the basic components of the die; various other components are installed and fixed on it. The plane size of the template, especially the front and rear direction, should be compatible with the workpiece, too large or too small is not conducive to operation. Some molds (blanking, punching molds) need to set up a backing plate under the mold base for the convenience of parting. At this time, it is better to connect the backing plate and the template with screws, and the thickness of the two backing plates should be absolutely equal. The spacing of the backing plates shall be subject to the parts that can be delivered and should not be too large to prevent the template from breaking. 6. Fasteners It includes screws, nuts, springs, pins, washers, etc. Standard parts are generally used. There are a lot of standard components of stamping dies, and the des...

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Plastic 3D Printing

Plastic 3D Printing Processes The three most established plastic 3D printing processes today are the following: Fused deposition modeling (FDM) 3D printers melt and extrude thermoplastic filaments, which a printer nozzle deposits layer by layer in the build area. Stereolithography (SLA) 3D printers use a laser to cure thermosetting liquid resins into hardened plastic in a process called photopolymerization. Selective laser sintering (SLS) 3D printers use a high-powered laser to fuse small particles of thermoplastic powder. used deposition modeling (FDM), also known as fused filament fabrication (FFF), is the most widely used form of 3D printing at the consumer level, fueled by the emergence of hobbyist 3D printers. This technique is well-suited for basic proof-of-concept models, as well as quick and low-cost prototyping of simple parts, such as parts that might typically be machined. Consumer level FDM has the lowest resolution and accuracy when compared to other plastic 3D printing processes and is not the best option for printing complex designs or parts with intricate features. Higher-quality finishes may be obtained through chemical and mechanical polishing processes. Industrial FDM 3D printers use soluble supports to mitigate some of these issues and offer a wider range of engineering thermoplastics or even composites, but they also come at a steep price. As the melted filament forms each layer, sometimes voids can remain between layers when they don’t adhere fully. This results in anisotropic parts, which is important to consider when you are designing parts meant to bear load or resist pulling. FDM 3D Printing Materials ABS for Many colors PLA PA12+CF TPU SLA 3D Printing Stereolithography was the world’s first 3D printing technology, invented in the 1980s, and is still one of the most popular technologies for professionals. SLA parts have the highest resolution and accuracy, the clearest details, and the smoothest surface finish of all plastic 3D printing technologies. Resin 3D printing is a great option for highly detailed prototypes requiring tight tolerances and smooth surfaces, such as molds, patterns, and functional parts. SLA parts can also be highly polished and/or painted after printing, resulting in client-ready parts with high-detailed finishes. Parts printed using SLA 3D printing are generally isotropic—their strength is more or less consistent regardless of orientation because chemical bonds happen between each layer. This results in parts with predictable mechanical performance critical for applications like jigs and fixtures, end-use parts, and functional prototyping. Common 3D Printing Applications Additive manufacturing can be leveraged for both rapid prototyping and production in aerospace, medical, automotive, and other large industry sectors. Examples of typical parts, include: Form and fit prototypes Housings and enclosures Engine components Medical devices Jigs and fixtures Fue injectors Snap Fits Heat exchangers and heat sinks Surgical Instrumentation

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Plastic Painted

What's the Plastic Spray Painting Plastic spray painting is a surface treatment method of spraying paint or film on the surface of plastic products. It uses a spray gun or spraying equipment to evenly spray paint on the surface of plastic products, forming a layer of paint film, achieving the goal of aesthetics, protection, and improvement of plastic surface performance. Plastic spray painting can improve the appearance quality of plastic products, provide personalized color and effect choices, and increase the durability and protection of plastic surfaces. When selecting painting materials and processes, attention should be paid to factors such as compatibility with plastic materials, adhesion, and chemical resistance to ensure that the painting effect meets the requirements. In addition, reasonable painting operations and environmental control are also crucial for the final painting effect. How to work of Plastic Spray Painting Basic Treatment:Clean and treat the plastic surface, including removing oil, dust, and other impurities. This can be achieved through cleaning agents, solvents, or mechanical methods such as sanding. Primer coating: Spray primer on plastic surfaces. Primer can enhance adhesion, fill small holes and uneven surfaces, and provide a good color foundation. Sanding treatment: Sanding treatment is applied to the plastic surface after the primer has dried to remove surface irregularities and prepare the coating surface. Top coat coating: Spraying topcoat, its color and appearance will directly affect the final appearance of plastic products. The topcoat usually includes a variety of color and effect options, such as matte, bright, metallic texture, etc. Drying and Curing: The paint film needs to be dried and cured at a suitable temperature to ensure complete formation and good durability. What's the Advantage of Plastic Spray Painting Aesthetics and decoration: Spray painting can provide rich colors and surface effects for plastic products, giving them a better appearance and decoration effect. Spray painting can make plastic products appear smoother and more uniform, increasing the overall beauty and attractiveness of the product. Occlusion defects: Plastic products may have some defects, traces, bubbles, and other defects during injection molding or other processing processes. By spraying paint, these defects can be obscured or reduced in visibility, improving the appearance quality of plastic products. Surface protection: Painting can provide a protective layer for plastic products to prevent erosion and damage from the external environment. Plastics themselves often have a certain sensitivity to ultraviolet radiation, chemicals, etc. By applying a paint layer, damage to the surface of plastics can be reduced and their color, appearance, and performance can be protected. Increase wear and corrosion resistance: Proper spray painting can increase the wear and corrosion resistance of plastic products, extending their service life. Special coating technology can enhance the durability of plastic products by endowing plastic surfaces with characteristics such as scratch resistance and chemical resistance.

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Die casting molding

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mould cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter, and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used. What's the type of die casting molding Aluminum Alloy Die-Casting If you need more information about the molding Learn More Zinc Alloy Die-casting If you need more information about the molding Learn More Magnesium Alloy Die-Casting If you need more information about the molding Learn More Steel Die-Casting If you need more information about the molding Learn More How to work of Die-casting Mold Preparation：Fixed the mold into the machine,usually consisting of two parts: the moved half and fixed half Heating Molten Material: According to the required materials, heat metals (such as aluminum alloys,zinc alloys, ) to a suffficicient temperature to melt them into a liquid state. Mold Closure: Merge the moved half and fixed half together to form a closed chamber Injection Metal:Molten metal is injected into a closed mold through the die casting machine. the process is usually controlled by a hydraulic system to ensure that metal fills whote cavity Cooling and Solidification:After metal fills the mold, mold will be rapidly cooled by cooling water or other cooling media,causing the molten metal to solidify rapidly Mold Opening:Once solidification is completed, the moved and fixed half will separate and uncover the meatl parts formed during the die-casting process Flash removal and Processing:Remove any defective parts such as flash edges and excess materials.then,processing steps such as cutting, polishing, punching, Surface treatment:Surface treatment of die-casting parts, such as painting,electroplating, anodizing, as needed to improve appearcance quality and anti-corrosion performance What's the main type of Finish for Die-casting Product There are several main reasons for surface treatment of die-casting products: Aesthetics and decoration: Through surface treatment, it can provide better appearance quality and decoration effect for die-casting products. For example, treatments such as spraying coatings, electroplating, or anodizing can present products with rich colors, glosses, and textures, enhance product aesthetics, and meet market demand and consumer aesthetic requirements. Surface protection: Some metal materials are prone to oxidation, corrosion, wear, and environmental impact, and surface treatment can provide a protective layer to extend the service life of the product. For example, electroplating or coating can form a corrosion-resistant barrier on the surface of die-casting products to prevent metal oxidation or damage. Improving functionality: Surface treatment can also improve the functionality of die-casting products. For example, special coatings can increase the friction resistance of products and provide better anti slip performance; Electroplating can improve conductivity and electromagnetic interference resistance. Blocking defects: During the die-casting process, some defects may occur, such as bubbles, protrusions, defects, etc. By surface treatment, these defects can be covered or repaired, making the surface of the product smoother and more uniform. Increase wear and corrosion resistance: Some surface treatment methods, such as coating, electroplating, etc., can improve the wear and corrosion resistance of products. This is very important for applications that require resistance to friction, chemical attack, or harsh environments, as it can extend the lifespan of the product and improve its performance. Spraying Coating Electroplating Anodizing Power Coating

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plastic injection molding

What is Plastic Injectiong Moudling Process? Injection moulding is a manufacturing process for producing parts by injecting molten material into a mould or mold. Injection moulding can be performed with a host of materials mainly including metals (for which the process is called die-casting), glasses, elastomers, confections, and most commonly thermoplastic and thermosetting polymers. Material for the part is fed into a heated barrel, mixed (using a helical screw), and injected into a mould cavity, where it cools and hardens to the configuration of the cavity, After a product is designed, usually by an industrial designer or an engineer, moulds are made by a mould-maker (or toolmaker) from metal, usually either steel or aluminium, and precision-machined to form the features of the desired part. Injection moulding is widely used for manufacturing a variety of parts, from the smallest components to entire body panels of cars. Advances in 3D printing technology, using photopolymers that do not melt during the injection moulding of some lower-temperature thermoplastics, can be used for some simple injection moulds. Some Thermoset material can be injection: Material Mold Temperature(°C) Melt Temperature(°C) Melt Pressure(MPa) PE 60-70 170-200 60-100 PP 80-90 160-220 70-100 PC 60-110 230-285 80-130 POM 90-120 160-190 80-130 ABS 50-80 170-200 60-100 PMMA 40-60 160-180 80-130 Surface Finish Options Draft angle requirements will vary by requested finish. Industry standard Mold-Tech finishes are also available. FINISH DESCRIPTION PM-F0 non-cosmetic, finish to Protolabs' discretion PM-F1 low-cosmetic, most toolmarks removed PM-F2 non-cosmetic, EDM permissible SPI-C1 600 grit stone, 10-12 Ra PM-T1 SPI-C1 + light bead blast PM-T2 SPI-C1 + medium bead blast SPI-B1 600 grit paper, 2-3 Ra SPI-A2 grade #2 diamond buff, 1-2 Ra What's main defect of injection molding? The complexity of the injection molding process, and the interdependence of the many variables involved, means that any molding defect may have several different causes, of which more than one may be present at any given time Problem Possible Causes Picture Sink Marks Melt temperature too high Insufficient material injected Insufficient dwell time Premature gate freezing Sharp variations in wall thickness Wrong gate location Part ejected too hot Cavity pressure too low Voids Volatiles from overheated material Condensation on granules Premature freezing of flow path to thick section Flow marks Melt temperature too low Weld lines Incorrect gate location mold temperature too low Burn marks Incorrect filling pattern Warping Melt temperature too low Incorrect part design Overpacking near gate Sharp variations in wall thickness Flow length too great Unbalanced multiple gates Part ejected too hot Inadequate or badly located ejectors Temperature variations between the mold halves Some Case From Xiamen wiesel Technology co.,Ltd

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