Asia Billion is a professional Automobile instrument panel plastic Injection mold maker as well as other automotive plastic moulds.This is one of the biggest mold what we made before , because the limit of our CNC machine and injection machine size, we subcontract the some of our machining process from our supplier, we design the mold , make the programmers and milling parameters by team , inspect the quality by our quality guys too. so it mold is well done after T4 samples around 4 months from placing with the order to mold mass production.
automotive plastic mold
Core surface finish:
Cavity surface finish:
No of Cavities:
1 x 1
Type of gating:
SVG Valve gate
ejector pin + ejector block +lifter
Slider and lifter material:
H13 with heat treatment and nitridation
Lead time for T1
Mold base steel:
more than 300 000 cycles
Place of Origin
Here Asia Billion show how we do for our Automobile instrument panel plastic Injection mold project, the details as below:
The instrument panel, referred to as dashboard too, is an important part of automotive interiors. In automobile interior parts, all parts related to the dashboard are collectively referred to as the dashboard assembly. The instrument panel and the auxiliary instrument panel form the main and auxiliary instrument panels. The instrument panel assembly is the largest assembly series of automobile interior parts. The main instrument panel body is divided into hard instrument panel and soft instrument panel according to its surface texture.
Hard instrument panel: It is directly injection molded, and is generally used in trucks, buses, low-end cars or tough SUVs;
Soft instrument panel: It is composed of injection-molded skeleton and foamed surface layer, it is generally used in middle and high-end cars.
In automotive interior parts, the dashboard is a component that integrates safety, comfort, and decoration. Automotive dashboards are generally divided into hard and soft. With the installation of airbags, soft dashboards safety requirements for people have been lost, so as long as the appearance quality is guaranteed, the use of low-cost hard instrument panels is completely feasible for all now.
Plastic parts material:
The material is PP + EPDM-TD20, and the shrinkage rate is 0.95%. filled by EPDM can improve the elasticity of plastic parts, the TD20 refers to the addition of 20% talc in the material, the purpose is to improve the stiffness of the instrument panel.
Plastic instrument panel features:
It belongs to large-scale plastic parts, and its overall dimensions are 1308.00mm × 526.00mm × 476.00mm, so the mold also belongs to large-scale injection molds;
The appearance of the instrument panel needs to be textured, and the draft angle of the side is ≥5°to facilitate the de-molding of the pattern.
The structure of the plastic dashboard is very complex, there are many bumps and insertion holes, and the melt flow resistance is large. Need to pay attention to the design of the gate and venting system.
Mould flow analysis:
Mold structure analysis:
1) Mold size:
Instrument panel injection mold adopts hot runner injection system, fixed and movable molds adopt integrated structure, mold adopts guide pin and parting line positioning guide structure, the maximum external dimension of mold is 2200mm × 1100mm × 1425mm
2) Design of gating system
In automotive instrument panel mold design, the hot runner is generally used in the hot runner system. There are two types of hot runner installation: integral and non-integral.
The mold adopts an integral hot runner and has the following advantages:
★ The whole hot runner can be easier for installation, which shortens the installation and disassembly time.
★ The requirements for the thickness of the hot runner sprue plate and the dimensional accuracy of the frame plate are not high, which reduces the manufacturing cost.
★ Because the hot runner is an integral assembly, there is no risk of leakage of the material.
★ The wires of the hot runner are all pre-installed in the metal frame, which will not cause damage to the wires during disassembly and damage the heating coil.
★ Because the hot runner is an integral assembly, the assembly between the components of the hot runner is assembled by professional personnel of the hot runner enterprise with professional tools, which can ensure the accuracy and reliability of the assembly, and does not require repeated disassembly and assembly in the future.
★ Low maintenance and repair costs.
The instrument panel is an appearance cosmetic part. When designing the hot runner of the mold of the automobile instrument panel, it is necessary to ensure that the welding mark is on the non-appearance surface or does not affect the appearance surface quality. This is the focus and difficulty of the mold design. Although the traditional simultaneous multi-point feeding can fill the entire cavity of the melting, but it is difficult to achieve the ideal quality of the plastic part due to the welding marks. For this purpose, the mold adopts sequential valve gate ( SVG) technology, and the opening or closing of 6 nozzles is controlled by the driving of the cylinder to achieve the effect of no welding marks on the surface of the plastic part.
3) Mold steel selection:
The dashboard is a large plastic part with a complicated structure, and the mold also belongs to a large injection mold. The parting surface is complicated. In order to improve the rigidity and strength of the mold and reduce the overall size of the mold, the template and molded parts adopt an integrated structure. There are many through holes in plastic parts, and the insertion angle of the moving and fixed mold inserts must be greater than 7 °. The fixed template material is 718, and the movable template material is P20 or 738 with hardening. Usually it can meet the mold life of 300,000 to 500,000 times.
For the slider on the injection mold of the automobile instrument panel, a coil spring is not used, but a nitrogen spring is used because the coil spring will fail for a long time and damage the mold. The choice of the spring size depends on the quality of the slider.
In order to make the plastic parts easy to take out after injection molding, the design requires that the slider be as small as possible above the parting surface, and that all sliders have the same size above the part surface. When the slider material is unloaded, the back of the slider should be used as a reference, which will save material.
4) Cooling system design
The uniform and reasonable cooling system has an important impact on improving the molding quality and shortening the molding cycle of plastic parts. Automotive instrument panels are appearance parts. When designing molds for forming appearance parts, the cooling system must ensure that welding marks are on the non-appearance surface of the plastic part or eliminate weld marks.
In the design of the mold, there are 12 pcs cooling channel on the moving molds and 20 pcs cooling in the fixed side. The moving and fixed mold water channels are arranged crosswise to form a waterway grid. This uniform cooling ensures the production efficiency of the plastic parts, it will avoid warping and deformation of the plastic parts, and effectively ensures the molding quality of the plastic parts.
For large injection molds, the guide positioning system directly affects the accuracy of the plastic part and the shot life of the mold. Four square guide columns are used for guiding between the mold moving and fixed molds. The four square guide columns are symmetrically arranged on the four sides of the fixed mold. Note that the position of the square guide columns cannot prevent the robot from removing the plastic parts. In addition, the square guide post must be at least 30mm higher than the highest point of the core to ensure that the square guide post first enters the movable mold when clamping, which effectively protects the core and cavity.
In order to ensure that the plastic parts can be smoothly pushed out, the pusher fixing plate of the mold is guided by four pusher plate guides, and a cone positioning structure is also designed and processed at each of the four corners of the mold. The inclination angle of the cone is 10 °. .
5) Demolding system design
The push-out of the plastic parts in the mold consists of multiple sets of push rod. Due to the large plastic parts, the demolding force and the resetting force of the ejector plate are relatively large. The demolding system uses 4 hydraulic cylinders as the power source. The surface of the moving model core is uneven, and the fixed ends of all push rods and push tubes must be designed to prevent rotation.
Asia Billion Plant Overview:
Common problems in mold manufacturing:
1.The approximate size range of the molds you can make?
The size of the mold can reach 2 meters in length, 1.5 meters in width, and weigh 10 tons.
2. Do you make hot runner molds?
Yes, we are proficient in using various hot runners, such as D-M-E, YUDO, Mold-master, Synventive, husky, PSG, HASCO, etc. For the mold you want to process, you can choose the hot runner system you are satisfied with.
3. File formats you can receive
We can receive different file formats, such as IGES, DWG, STEP, PRT, X_T, PDF, etc.
4. Processing accuracy of equipment:
We can process steel to a tolerance of 0.005mm, and at the same time, injection molded parts can achieve a tolerance of up to 0.02mm. Different product designs and materials are suitable for different tolerance requirements. Generally, the higher the factory requirements, the more complicated the structure, the more expensive the price and the longer the delivery time.
5. Type of mold steel:
We are happy to use all common types of mold steel, such as 1045, 1050, P20, P20HH, 718H, 738H, H13, 2738, 2083, 2316, 2343, 2344, 8407, SKD-11, SKD-61, S136, S136ESR, S7, NAK80 and so on. We can choose the steel according to your requirements, or we can help you choose the mold steel according to your production quantity and basic requirements.
6.What plastic materials do you use?
ABS, PP, PC, PE, HDPE, POM, PA6, PA66, PA6 + GF, PS, PMMA, TPU, TPE, PVC, and various engineering modified plastics. We have rich experience in the injection molding process of these materials. Parameters to get the perfect plastic product.
7. Delivery of mold:
The delivery time of our mold is usually 3 weeks to 15 weeks, which often depends on the complexity and size of the mold, as well as the processing accuracy. Fast molds and simple molds can usually get the first samples in 3 weeks, and ordinary small and medium molds can usually get the first samples in 4-6 weeks. The final delivery time of the mold also depends on the number of times the customer changes the mold and the speed of feedback. Don't make final inferences here. Mature products usually go through the mold within 2 to 6 weeks after the first sample. Immature products usually change more, so more time is required.
8.How to pack and transport the Automobile instrument panel plastic Injection mold ?
When the mold is finished, we will apply a layer of anti-rust paint on the surface, and then wrap it with a plastic film, wrap it and put it in a sterilized wooden box.
1). Assembly drawing of A1 paper size and all relevant drawings of the electronic draft
3). Description of rings and screws
4). Material certification and heat treatment report
5). Operating instructions for special molds or paper loading
6), Dimension report
9. Do you sign nondisclosure agreements ( NDA)?
Yes. We understand the importance of design to you. It is also our company's policy to sign a nondisclosure agreement. Without your permission, we cannot publish or copy to third parties the design and concept of your company's products or your company's information.