What process can be used to avoid deformation or cracking of the Sensor Shell in the later stage?

The choice of materials directly affects the dimensional stability and mechanical properties of the Sensor Shell. ABS and PC are commonly used engineering plastics, but their shrinkage characteristics are different. The use of PC/ABS alloy can better balance the shrinkage rate and reduce the internal stress caused by material differences. For applications with special requirements, you can consider adding modifiers to improve the stability of the material. Before injection molding, the raw materials must be fully dried. In particular, PC materials are very sensitive to moisture, and insufficient drying will cause brittle cracking and other problems in the product. It is recommended to use professional drying equipment and strictly control the drying time and temperature to ensure that the material reaches the best processing state.

Mold design is a key factor affecting the quality of the Sensor Shell. Reasonable gate design can improve the flow state of the melt and reduce the generation of weld lines and internal stress. The use of multi-point gate layout can make the plastic fill the cavity more evenly and avoid local stress concentration. Uneven cooling will cause inconsistent shrinkage of various parts of the product, thereby causing deformation. The cooling water channel of the mold should match the shape of the product and cooperate with a precise temperature control system to ensure uniform temperature distribution throughout the molding process. The design of the demolding mechanism also requires special attention. Proper demoulding angle and balanced ejection system can avoid unnecessary mechanical stress on the product during demoulding, thereby reducing the risk of deformation and surface damage.

The setting of injection molding process parameters has a direct impact on the quality of Sensor Shell. The control of melt temperature is particularly critical. Too low temperature will lead to insufficient filling, and too high temperature may cause material degradation. It is necessary to select a suitable processing temperature range according to the material properties. The setting of injection speed and pressure also needs to be optimized. Too high injection speed will increase molecular orientation stress, so it is recommended to use medium and low speed injection. At the same time, the use of a reasonable pressure holding strategy can effectively compensate for shrinkage and reduce residual stress inside the product. The control of mold temperature should also not be ignored. Appropriate mold temperature helps to improve material fluidity and reduce molding stress. For different materials, the corresponding mold temperature range needs to be set and kept stable throughout the production process.

The post-processing process after injection molding is very important for eliminating stress in the Sensor Shell. Annealing is an effective stress release method. By heating the product to a specific temperature and holding it for a certain period of time, the residual stress can be significantly reduced. After annealing, it should be cooled slowly to avoid new stress caused by sudden temperature changes. The management of the storage environment should not be ignored. Some materials are prone to moisture absorption in a humid environment, which may lead to stress cracking and other problems in subsequent use. Therefore, the finished product should be stored in a dry environment and, if necessary, moisture-proof packaging should be used.

Various quality problems may be encountered in actual production. For deformation problems, it is usually necessary to check the cooling system and pressure holding settings; cracking problems are mostly related to internal stress, and it may be necessary to adjust process parameters or add annealing steps; dimensional instability is often caused by process fluctuations or mold wear, and process control and mold maintenance need to be strengthened.