Project Background
The client is a Japanese electronic component manufacturer, primarily producing connectors for industrial and automotive applications. They wanted to develop a high-density pin-type electronic connector housing mold. The requirements included a long mold life, high dimensional accuracy, and high production efficiency to meet their needs for high-volume automated production.
The connector has a complex structure and extremely thin plastic parts (only 0.3mm at its thinnest point), placing extremely high demands on the mold’s precision and stability. Ordinary mold manufacturers would find it difficult to meet their standards.
Our Solution
During the project initiation phase, our mold engineers worked with the client to evaluate the product design. Ultimately, we proposed a customized solution to address the key technical challenges:
- High-Precision Mold Design
Utilizing high-precision imported mold steel (such as S136H/H13) and performing mirror polishing to ensure pin hole accuracy and wear resistance. - Advanced Machining Technology
Using CNC precision machining, wire EDM, and mirror EDM to achieve mold part tolerance control within ±0.005mm. - High-Efficiency Cooling System Design
- We employ a multi-point water cooling structure within the mold, significantly shortening the injection molding cycle and improving production efficiency.
- Automated Demolding System
- For complex pin structures, GBM engineers designed a precision-engineered ejector and insert mechanism. This design ensures smooth demolding and prevents product deformation.
Project Results
Mold Manufacturing Cycle: 30 days
First Trial Success Rate: 100%
Mold Life: Over 800,000 cycles
Production cycle per mold reduced by approximately 20%
Excellent product dimensional consistency, meeting the customer’s automated assembly requirements
The customer was very satisfied with the mold’s stability and lifespan. They subsequently placed additional mold projects for several similar connector products and established a long-term cooperative relationship.
