In the fields of high-density products such as 5G connectors and medical catheters, a dimensional deviation of ±0.01mm can lead to product scrapping. High-precision vertical injection molding machine manufacturers have pushed the equipment accuracy to a new height by relying on five core technology systems. This paper deeply disassembles its technical code and reveals the implementation path of micron-level forming.
1. Ultra-dense Screw Assembly: "Micron-level Precision" for Melt Transportation
The screw is made of double alloy material (surface hardness HRC65+), and the depth error of the screw groove is ≤±0.005mm in combination with the CNC grinding process. The "asymmetric thread design" unique to a certain leading manufacturer enhances the uniformity of the shear heat of the molten material by 30%, making it particularly suitable for the molding of heat-sensitive materials such as LCP. The gap between the screw and the barrel is controlled at 0.01-0.03mm to ensure the plasticizing accuracy and stability.
Ii. Nanoscale Mold Positioning System: The "Golden Partner" for Mold Closing Accuracy
The positioning pins of the mold adopt the HSK-E32 standard interface and are combined with the laser alignment instrument to achieve coaxiality at the 0.002mm level. A certain medical equipment dedicated model is even equipped with a magnetic levitation mold adjustment device. Driven by a linear motor, the parallelism error of the template is controlled within ±0.003°, ensuring the consistency of thin-walled products (with a wall thickness of less than 0.3mm) in forming. Iii. Full Closed-loop Servo Control System: "Dynamic Balance" of Pressure and Displacement
Deploy the linear grating ruler (with a resolution of 0.1μm) and the pressure sensor (with an accuracy of ±0.1% FS) to construct a dual closed-loop control of position and pressure. When the pressure fluctuation in the mold cavity is detected to be greater than ±1MPa, the servo motor adjusts the injection rate at a response speed of 1ms. The actual measurement by a certain 3C connector manufacturer shows that this system has reduced the defect rate of pin offset in the Type-C interface from 0.8% to 0.15%.
Iv. Revolution in Temperature Control Accuracy: The Pursuit of ±0.5℃
By adopting the PID + fuzzy control algorithm and combining with the nano-scale ceramic heating ring, the temperature control accuracy of the barrel is improved to ±0.5℃. For mold cooling, the microchannel heat exchange technology is introduced. Through simulation to optimize the waterway layout, the uniformity error of mold temperature is made to be less than ±1℃. A production case of optical lenses shows that this temperature control system helps keep the light transmittance fluctuation of the formed products within 0.3%.
V. Vibration Suppression Black Technology: Micron-level Motion Stability
The base adopts a honeycomb cast iron structure (with a damping ratio increased by 40%), and is combined with an air spring shock absorption device to control the vibration value of the equipment operation below 0.05g. The key transmission components (such as ball screws) adopt a pre-stretching process to eliminate the influence of thermal expansion and ensure that the long-term operational accuracy attenuation is less than 0.002mm per year.
Technical verification system: Full-chain guarantee from design to mass production
Leading manufacturers generally establish a dual-track mechanism of "digital twin + physical verification" : simulating melt flow through Moldflow and combining CT scanning to analyze internal shrinkage marks; Before mass production, a 72-hour continuous mold trial was conducted, and over 100,000 sets of data were collected to optimize the process window. A case of a certain semiconductor packaging equipment shows that this verification system has shortened the new product introduction cycle by 35%.
