New Material Injection Molds: How Does Fanstar Solve The Pain Points of New Plastics in One Move And Increase The Yield Rate by 30%

In the fields of new energy vehicles, wearable medical devices, and 5G communications, the iteration speed of new plastics is unprecedented. However, when enterprises put new material injection molds such as PA12, LCP, PPSU, and PEEK into mass production, they frequently encounter four major pain points: high-temperature warpage, high glass fiber wear, dimensional drift, and long cycle. Fanstar's new material injection molds reshape the mold design logic with a complete set of "material-level thinking", solving these problems from the source.

Pain point one: High-temperature warping

The processing temperature of new types of plastics is generally above 300℃, while traditional steel materials have uneven heat conduction, resulting in warping of the finished products and large internal stress. Fanstar's new material injection molds are made of the improved 8407 steel from Sweden, and 3D printed conforming waterways are embedded in the key areas of the cavity. The cooling efficiency is increased by 40%, and the warpage is ≤0.05mm.

Pain point two: High fiberglass wear

PPA and PPS containing more than 30% glass fiber can erode the gates, ejector pins and cavities of molds as much as "sandpaper". Fanstar's new material injection molds feature tungsten steel inserts on the gate sleeves, with a DLC coating on the surface that has a hardness of HV4000. Even after 500,000 continuous production cycles, there is no flash, saving customers the cost of downtime and part replacement.

Pain point three: Size drift

The new material is extremely sensitive to changes in shear rate and holding pressure, and the error of traditional mold flow analysis is greater than 5%. Fanstar's new material injection molds have built their own "material database", directly importing the melt index and shrinkage rate of each batch into Moldex3D to achieve three-dimensional coupled simulation of "material - process - mold", with a size CPK of ≥1.67 and direct access to the SMT assembly line.

Pain point Four: Long cycle

From T0 to mass production, the traditional model takes 3 to 4 months. Fanstar's new material injection molds adopt concurrent engineering: steel ordering, heat treatment, five-axis precision machining and mold testing are carried out simultaneously, with the first batch of qualified samples delivered within as fast as 28 days. At the same time, we offer a "cloud mold trial" service, allowing customers to remotely and in real time view molding parameters, reducing business trips by 50%.

When "material innovation" becomes the core of terminal competition, molds must be upgraded simultaneously to "material grade". Fanstar's new material injection molds enable every material innovation to be quickly and stably transformed into a market advantage. Contact us immediately to get a dedicated new material injection mold solution and turn concept plastics into best-selling products together!