How to Source Mold Projects Better | Machine Choice, Steel Grades, One Supplier

Eliminate multi-party docking, reduce 40% communication cost, make project delivery shorten 10 days, realize machine table and material's high efficiency coordination.

Machine Choice

Tonnage & Clamping Force

One machine injection machine uses hydraulic big iron rod takes two pieces add up heavy 300 kilograms' steel plates dead dead push live. Mold middle exactly towards inside squeezes 280 degrees Celsius' high temperature polycarbonate plastic water. Injection machine inside that root big long screw rod according to per second 120 millimeters' speed towards inside pushes, hard live live makes out 180 megapascals' pushing force.

Machine must use out drink milk's strength press live this strand pushing force. Factory inside machine shell on printed's "200T", points' exactly is can take iron blocks hug dead not let it open's strength. Less give one ton's strength, liquid state plastic following gap towards outside runs. Cooling demold take out come one look, part edge formed out a circle 0.08 millimeters thick's hard raw edge.

Old worker calculate this pen account has a set specific's method. Take ruler calculate out part flat spread on desk face on occupies how big area, holding number go multiply different plastics' flow pushing force number. Very common's household appliance plastic shell, use one square inch's area to convert, roughly wants to eat away 2.5 tons' equipment supporting force.

Distance injection mouth closest's place measured out come's pressure high reaches 120 megapascals, flows to most edge corner's place drops to 30 megapascals. Deal with extremely violent's pressure change, machine set's pushing force towards up extra leave 15% to 20%'s surplus amount counts as a hard indicator.

· Soft rubber PP and PE plastic: one square inch give 1.5 to 2 tons force

· Common's ABS and PS materials: need 2.5 to 3 tons' equipment support

· Hardness high's PC or POM material: machine pushing force wants towards up add to 3 to 4 tons

· Mixed 30% glass fiber's nylon: needs add weight to 4 to 5 tons

Different formulas' plastic particles towards machine tonnage's appetite completely not same. One length width each 10 centimeters' square shape outer shell cover, calculated down projected area 100 square centimeters. Take ordinary ABS plastic particles go process, onto 90 tons' equipment completely presses live. Change into that kind added glass fiber's nylon material to hit, wants to hire one machine 150 tons' machine to do work.

Look for large size's machine do work add money specially ruthless. Processing billing table on's numbers rise very steep. 120 tons equipment's market price basically is per hour 22 US dollars. Some black heart factories fear delay delivery goods date, take small small's mold frame on idle's 400 tons machine table on start work. Large size machine one starts move, one hour consume electricity amount runs to 35 degrees.

Count on machine depreciation fee and machine repair worker's maintenance fee, 400 tons machine per hour charge marked to 65 US dollars. Take a 5 ten-thousands pieces' plastic small order come calculate account, single piece production cost flat white no reason added on 0.03 US dollars. Place order's buyer even look all not look machine grows what shape, give factory inside this machine idle's big iron lump extra pulled out 1500 US dollars processing fee.

Brute force give too big wants to ruin mold inside's precision parts. 400 tons' hydraulic brute force all smashes on only can bear 150 tons pressure's ordinary P20 steel material on. Two pieces steel plates fit gap inside used to exhaust waste gas's 0.02 millimeters small concave groove, do not reach 1 ten-thousand times just by hard live live pressed flat.

· 0.02 millimeters exhaust groove by steel plate pressed flat thoroughly closed dead

· Responsible take parts push out come's tiny iron pillar deforms stuck dead

· Mold fit face appears 0.1 millimeters deep's ugly concave pit

· Thick big's metal guide pillar surface wear and tear intensifies early scrap

Exhaust not out go's air by violently squeezed, temperature soars to 600 degrees above, takes white color's plastic surface burns out ugly's black spots. Repair these deformed's steel materials re-onto large scale milling machine go shave away one layer, originally promised can hit 30 ten-thousands times' mold, not reach 5 ten-thousands times became a pile waste iron. Change into strength small's machine do work will issue other messes.

Take 90 tons' machine go press 120 tons just can get done's large size product. Injection fast finish that last 0.5 seconds, 150 megapascals' internal pushing force hard live live takes closed's machine pushes open a strip 0.05 millimeters' fine seam. Drawing on clearly clearly writing outer diameter 50.00 millimeters' plastic gear, from mold inside take out come one measure became 50.15 millimeters.

Assembly line on's assembly workers holding become big's gear, just is stuff not into transmission shaft's install hole position inside. Injection machine give pushing force's method divided into several big classes, most common old style machine model uses four metal thick joints go pry move. Machine relies on lever principle, takes hydraulic oil cylinder inside 50 tons' strength magnifies four times, becomes 200 tons' rigid lock dead state.

Metal joints inside lacked lubricating butter, ground out 0.1 millimeters big's gap, this magnified's number became empty's. Year old's old machine oil pipe aging leaks oil serious, outer shell plate on writing 200 tons, actual measure even 160 tons' strength all squeeze not out come. Japan FANUC leave factory's 150 tons all electric machine, leave factory book white paper black words writing strength error not exceeds percent of one.

Shoot Glue Amount & Contain Mold

Workshop old workers manage it call tie bar. Four roots pillars surround into a four square frame, dead dead stipulated mold can put how big. One machine 200 tons' common machine model, pillar internal's up down left right spacing basically is 460 times 460 millimeters.

Crane hoisting a piece weighs up to 500 kilograms' mold steel block towards machine table inside stuffs. Operator hand inside operate crane produces weak shake, steel block in mid air inside will have 15 millimeters around's swing amplitude. Mold outer surround dimension do to 440 millimeters wide, put in go two sides just only left mere 10 millimeters' gap.

Hoist install time ice cold's steel block extremely easily heavy heavy hits on guide pillar on scrapes out deep pit. Experience rich's open mold master will forcedly leave out single side 30 millimeters' safe distance. 400 times 400 millimeters' mold bottom plate stuffs into 460 millimeters' frame inside do work exactly good.

Thickness data similarly limited dead machine's running physical range. Equipment nameplate manual on marks clear contain mold amount is 200 to 500 millimeters. Design drawing on's mold total thickness by pressed flat became 180 millimeters. Machine hydraulic big iron rod pushes to mechanical set's furthest limit position stuck dead.

Two pieces steel plates middle still has 20 millimeters' gap close not on. Part supply goods party figures save trouble, look for a piece 30 millimeters thick's waste iron plate pads at back side make up number. Pad plate purely relies on few roots long screws hard pulling, every day bears huge force hit, hit full 2000 mold times absolutely must happen thread loosen slip wire.

· Take mold outline width go compare equipment tie bar inner distance, leave enough safe gap.

· Calculate product height add on demold need's mechanical arm grab take space, get out open mold stroke.

· Check verify mold closed after's total thickness, compare equipment marked nominal's minimum contain mold numerical value.

· Confirm single time shoot out plastic total weight falls at machine maximum capacity's reasonable percentage inside.

Machine material barrel inside has a root carrying spiral thread's long iron rod at continuously rotating. 120 tons machine matches on a root outer diameter 35 millimeters' screw rod, loads full exactly can melt open 150 grams' PS plastic water.

Arrange produce's plastic outer shell single piece net weight 12 grams. Attach a strip used to guide flow's 8 grams waste material cold runner, one mold total altogether consumes 20 grams material. 20 grams divides machine full load's 150 grams, occupy proportion drops to pitiful's 13%. Trade inside has a path dead order, single time shoot glue amount resolutely cannot lower than full load's 30%.

Every time only uses away 13%'s material, left down's plastic all muffled in 260 degrees high temperature's metal cannon barrel inside line up. A batch material in high temperature environment inside fully baked 8 minutes just by pushed out come. Originally crystal clear's polycarbonate material, high polymer chain at 5th minute just starts heat break.

Out come's transparent outer shell all carrying a strand like old teeth same's turn yellow bottom color. Change a weighs up to 130 grams' big part onto machine table test. 130 grams occupied 150 grams full load capacity's 86%, exceeded 80%'s safe shoot out red line.

Gun chamber inside even a little little buffer replenish pressure's residual material all not leave down. Injection procedure last 0.2 seconds needs maintain 100 megapascals' high pressure takes internal plastic fills tight solid. Material barrel sees bottom, pushing force in one instant returns zero. Plastic part on that piece 5 millimeters thickness's thickest part, gets not to new liquid's squeeze replenish.

Cool demold take out come measure, surface caves in down go a 0.5 millimeters deep's big pit. Purchase party holding a handful flat plastic square plate's drawing go factory talk price. Square plate itself very thin very light only has 40 grams, outer surround length width dimension expanded to 350 times 350 millimeters.

Want to take this piece big square plate mold stuff into tie bar middle, factory inside forced not get already calls uses one machine internal spacing 520 millimeters' 250 tons medium type machine. 250 tons machine single time can spray out 530 grams plastic water. 40 grams' product put in go hit, capacity occupy proportion drops to 7.5%.

Guard against plastic in cannon barrel inside bake char carbonize, adjust machine master hardens scalp takes heating coil temperature from 240 degrees forcedly towards down adjust low to 210 degrees. Plastic temperature reaches not to standard, flows into mold cavity's action becomes very viscous sluggish.

One ten-thousand big flat plates produce out come, surface all is like tiger skin same's cold material ripples. Equipment space and capacity parameter's wrong position match early just lets this batch goods became defective products. Get to audit drawing report, look for right top direction that marked percentage's separate square frame.

Frame inside clear writes clear product combined waste material's total weight is 65 grams. Corresponds chosen use's 160 machine table maximum shoot out amount is 240 grams, occupy proportion stuck at 27%'s health data line on. Go workshop look hit sample, circle to machine table side face look for that sheet aluminum made leave factory nameplate.

Drive & Position

Old style oil press machine always carries has low deep's hydraulic pump buzzing sound, machine back side hangs a loaded full 150 liters viscous hydraulic oil's big iron box. All electric machine table do work quiet silently, back part only has few roots thick big's cables connects four huge's servo motors.

Relies on hydraulic oil pushes big iron rod towards front rush, carries has unable wipe out's physical temper. Morning 8 o'clock just open machine room temperature 20 degrees, pipe inside's hydraulic oil flows issues sticky. Afternoon two o'clock workshop air temperature rises to 35 degrees, machine continuously do work takes oil temperature burns to 45 degrees towards up.

Oil becomes thin pushing force just easily slip. Drawing sets screw rod towards front pushes 50.00 millimeters must stop down. Hydraulic valve close on that one instant, thin's oil liquid will carry huge physical inertia towards front extra slide 0.3 millimeters.

"Use flowing's oil liquid go brake live 150 megapascals' sprint force, oil temperature differences a 5 degrees, every time stop down's position all will have zero point several millimeters' drift."

Mold inside's cavity space volume is fixed's. Extra stuff in go 0.3 millimeters volume's high temperature plastic, part take caliper one measure thick 0.05 millimeters. Make thicken wash basin or toy car shell, extra out 0.05 millimeters dimension's naked eye fundamentally distinguish not out come.

Change into high density's electronic connector, situation happened deflection. One root index finger long's small long strip on, dense dense numb numb lines up 60 tiny's copper pin insert holes. Every hole's plastic wall thickness merely only has 0.15 millimeters.

· 0.15 millimeters' thin wall bears not live extra plastic instant inject's strong pressure.

· Oil press machine extra slides 0.1 millimeters, thin wall just will produce naked eye can see's bend deform.

· Tolerance requires controlled at ±0.01 millimeters' drawing, oil press valve guard not live data red line.

Pull out oil pipes change onto full set ball screw. Four large size servo motors took over open mold, shoot glue and keep pressure all mechanical actions. Motors completely receive computer board sends out's digital pulse signals go do work.

Set 10000 electric pulses equals towards front walk 1 millimeter. Computer board cuts off signal, motor drives' screw in 0.01 seconds within finishes physical emergency brake. Set stop at 50.00 millimeters' position, one whole day run down come error stuck in 0.005 millimeters' extremely small circle inside.

Make a pair VR glasses inside's transparent resin lens. Lens center thickness on drawing marks clear is 2.45 millimeters. Dimension tolerance requires dead dead bites in ±0.003 millimeters' range inside.

Ordinary oil press machine hits out come's lenses, one mold thick 2.47 millimeters, next one mold thin 2.43 millimeters. Light ray pierces through thick thin not even's plastic piece happens serious's refraction shift. Buyer puts on finished product helmet look screen, not out three minutes just will head dizzy nauseous.

"Take ordinary's machine table hard hit high precision tolerance orders, factory only can at production line beside place on high magnification magnifying glass, relies on manual takes large amount dimension drifting's defective products pick out come throw into waste material bucket."

Scrap rate soars high pay bill party becomes place order's purchaser. Thrown away's 30% waste material cost by supplier converted entered single piece processing fee inside. Look factory hands over come's quote detail table, machine shift fee that column hiding doorway.

One machine 150 tons' brand new hydraulic machine sell price at 3 ten-thousands US dollars up down. Same body size's Japan imported all electric machine table, purchase price soars to 8 ten-thousands US dollars. Buy machine's capital difference pulls open per hour processing fee's gap.

Steel Grades

P20

Material inside contains about percent of 0.3 to 0.4's carbon component. It leaves factory just carries HRC28 to 32's hardness, take back go not need put into high temperature furnace inside re-burn. Machine tool operator takes whole piece iron clamps on table face on, rotate speed opens to per minute 4500 revolutions towards down cut, cutter blade good good's.

A piece wide 600 millimeters long 800 millimeters' ordinary bottom plate, thrown to weighbridge on number approaches 850 kilograms. According to market spot goods price per kilogram 22 bucks money walk account, purely buy this piece blank iron just must spend away one ten-thousand eight thousand bucks. Encounter hollow out make large dimension display rear shell's work, every day by lathe shaved down come's curled waste iron chips just can weigh out three forty kilograms.

· Single time towards down cutting depth reaches 5 millimeters

· Line cutting machine per hour cuts away 4000 square millimeters

· Flush water pipe add pressure sprays out per minute 20 liters cooling liquid

· Initial cutting after reserve 0.5 millimeters thickness slowly repair

Polishing master holding 800 grit's sandpaper go rub surface, grind break skin also only can make out that kind half matte's frosted feeling. Hard takes it move to polishing machine on change 2000 grit wool wheel grind, metal surface will pop out 0.02 millimeters big small's orange skin same pockmarks. Take strong light flashlight paste close shine past, reflection layer bottom under hiding dense dense numb numb's tiny pits.

Machine tool processing master quite likes make this kind lean soft's material. From warehouse draw a handful diameter 12 millimeters' tungsten steel cutter, machine continuously turns on 8 hours just grinds blunt a little go change cutter. Calculate down spread to every plastic piece on's cutter tool loss money even one cent money all not reach. Make carrying deep pit's tool box outer shell, machine tool starts move three days two nights just takes internal shape digs a bottom towards sky.

· Surface nitriding treatment bites in go 0.15 millimeters

· Nitride finish surface layer hardness breaks through HV600

· Spray WD-40 anti-rust oil film thick 5 micrometers

· Machine mold temperature highest by locked in 120 degrees inside

Beside connects two roots rubber pipes, circulation water temperature always controlled at 15 degrees to 25 degrees between runs. Injection machine's thick iron rod takes burned to 220 degrees' melted plastic squeezes into iron shell inside. Water path drawing draws somewhat compact a bit, pipes between mutually separated 15 millimeters cloth a strip 8 millimeters thick's water path. Whole cooling open mold's time pressed in 25 seconds within, one hour properly extra squeezes out 50 products.

Every day by several tens tons' strength hits open close. Ordinary plastic continuously hits full 30 ten-thousands mold times around, iron block joint seam's edge place will by ground away 0.05 millimeters wide's a strip small seam. Just drops off falls into basket inside's plastic shell surround edge, extra out a circle cuts hand's plastic thin edge. Engineering department only can driving forklift takes half ton heavy's guy transports back workshop, look for old welder takes gap burn weld mend flat.

Welder pinches live 0.8 millimeters fine's welding wire, current knob twists to 60 amperes facing gap light fire. Newly mended on's metal point cools through after, hardness towards up jumps breaks HRC45. Assembly master takes steel file knife go scrape that bulges up's place, hand feel with take blunt cutter blade scrape cement ground same dry astringent. Drawing changes come changes go in same one place burn welds three rounds, several centimeters thick's iron plate receives heat will slant away 5 threads.

· Buy iron's money occupies whole sheet quote bill percent of 20

· Add install hot runner enter glue wants to extra spend 8000 bucks

· Ejector pin round hole's tolerance bites dead at plus 0.015 millimeters

· Load goods' wooden box bottom bear weight according to 1.5 tons calculate

Foreigner sends over come's purchase list inside often writes a Germany number 1.2311. Encounter picky a bit's people, salesperson will persuade him add money buy upgraded version's 718H. Material inside nickel metal's proportion from percent of 0.5 stiffly pulls high to percent of 1 up down. Whole piece material's hardness follows rises to HRC33 above, can let that set 65 inches TV machine rear shell extra resist live 8 ten-thousands times' high pressure injection.

Some small factories figure cheap go buy several thousands bucks one ton return furnace waste iron made out come's off-brand material. Cutter towards deep inside digs to half, bumps into hiding in inside diameter 3 millimeters big's sand hole. Spends 40 work hours stay up night carves out come's half finished product immediately thrown into waste material pile. Not only puts in go two handfuls 200 bucks money's white steel cutters, machine tool bearings by shaken to ga-da ring, look for people repair lathe again must consume away half month.

H13

Warehouse shelf lowest layer usually lying several pieces black dark's iron lumps, label on crooked crooked writes 1.2344. Receive down over millions output's order all relies on it come carry. Inside mixed percent of 5 around's chromium metal, resist make capability towards up lifts a big chunk. Not enter high temperature furnace before, hardness only has HRC20 up down, touches up come with ordinary soft iron block no what two kinds.

Masters habit taking advantage of it still is soft spongy's state, hurry move to CNC processing center takes outline contour give hollow out. Pre advance leave out about 0.2 millimeters' processing allowance, guard against back face burn red quenching time happens dimension shrink deform. Drill machine operator one mouthful breath hits through 40 diameter 10 millimeters' ejector pin holes, twist drill bit retreats out come time blade edge still pops a wisp white smoke.

Heat treatment factory's truck afternoon three o'clock punctually drives in come receives away several pallets half finished blanks. Worker takes it throws into vacuum furnace inside one road dry burns to 1020 degrees Celsius. Pumped dry air's furnace chamber inside not need worry iron block surface oxidizes raises skin. Drop temperature after still must put in go make two times 500 degrees above's high temperature tempering, takes metal internal holding's that strand stress give thoroughly release out come.

Three days after iron block pulls back workshop, Rockwell hardness tester's probe heavy heavy presses down go, dial plate on's pointer dead dead nailed at HRC52 on. Want to take ordinary white steel cutter up go scrape one layer iron skin, cutter edge on spot collapses into three gaps. Only can change onto coated titanium nitride's black bright hard alloy milling cutter, cutting sound sharp to let people teeth sour.

· Cutting feed speed forcedly drops to per minute 150 millimeters

· Spindle load meter often jumps to percent of 85's red line

· Spark machine discharge processing consumes purple copper electrodes much reaches 3

· Slow wire water tank inside cuts 10 millimeters plate wants to consume two hours

Electric spark machine table's oil tank inside soaking large half piece iron, distributes pungent's kerosene smell. Discharge gap dead dead stuck at 0.05 millimeters, copper male (electrode) little by little towards down bites go burns out complex's strengthen rib concave grooves. Discharge leaves down's white bright hardened layer has nearly 20 micrometers thick, hardness surprisingly high, fitter must take ruby oil stone pure hand work little by little rubs away.

Many car parts drawing on marks clear plastic raw material wants to add percent of 30's glass fiber. Several tens thousands roots naked eye sees not see's glass dregs mixed in 280 degrees melted's nylon material inside, by machine screw rod like high pressure water gun same violently sprays out come. Every day two three ten thousands times' high pressure flushes washes, change to soft a bit's iron early just by ground flat clear's edges corners.

Hard resists high strength's physical friction, machine supports to 80 ten-thousands times injection's time, dismantles open come look inner cavity surface still bright light like new. Carries inverted buckle's complex structure parts demold extremely smooth. Boss flipping account book calculates single piece share spread, two three dimes money's mold depreciation fee early by huge's ship goods quantity spread thin to decimal point back three digits.

Slightly has a point requires' car factory dispatches people come verify factory, points name says surname wants to use electro-slag remelting level's material. Steel plant takes big iron ingot re-melts filters one pass, inside percent of 0.01's sulfur and phosphorus impurities by sucked clean clean net net. Spends 75 bucks money one kilogram buys back come's high price goods, go polish absolutely not will pop out disgust people's small black spots.

Hardness too high's price is heat conduction becomes bad, heat transfer rate drops to 24 W/(m·K) around. Pipe worker master drills transport water holes must extra spend several times mind thought, water path distance product surface's distance live live shortens to 12 millimeters. Water chiller takes 5 degrees' ice water desperately towards pipe inside hits, hard is takes 15 seconds' molding cycle give snatched comes back.

Factory manager most fears encounters winter open machine not give mold preheat's rash young fellow. Iron blocks cold icy icy's, shoots in come 300 degrees' high temperature plastic, cold hot alternates five six hundred times after, four corners easily burst open naked eye hard distinguish's spider web shape turtle cracks. Repair mold group through the night uses angle grinder takes crack open digs open 5 millimeters deep prepares remedy.

Welder wearing protection face mask, takes H13 special use's same material welding rod go fill pit. Burn weld before must take big fire gun takes iron plate bakes to 300 degrees keep warm. Otherwise second day morning one look, weld point beside exact guarantee cracks open a strip half millimeter wide's big mouth. One pass toss down come, delivery goods date towards back delays whole whole three days.

S136

Unit price soars to 80 to 120 bucks money one kilogram. Buys a piece length width 500 millimeters, thick 80 millimeters' plate, three ten-thousands bucks money budget just dials out goes. Inside mixed percent of 13.6's chromium element, nature born carries prevents grow rust's physique.

Encounters burns to 200 degrees issues soft's PVC plastic, pops out come's hydrogen chloride gas can take ordinary iron plate smokes out a layer yellow color's iron rust. Changes onto contains chromium amount high's material, even anti-rust oil's money all saves away.

Sends go heat treatment factory's vacuum furnace inside burns to 1030 degrees. Pulls back fitter table, hardness tester's needle head one pokes, HRC data stops at 50 to 52 between. Machine tool master changes onto carries coating's four flute tungsten steel milling cutter towards down cuts. Spindle rotate speed opens to 3500 revolutions, high temperature cutting down come's metal broken chips extremely easily sticks dead at cutter edge on.

· Cutting liquid mix water proportion from 1 to 20 adjust thick to 1 to 15

· Single time down cutter depth honestly pressed at 0.15 millimeters

· Wire machine cuts 15 millimeters deep's groove extra consumes time 40 minutes

Polishing room's Old Yang wearing prevents dust mask, work table lamp pulls to distance iron plate 10 centimeters' place. First uses 600 grit sandpaper takes lathe leaves down's rough cutter marks little by little scrapes flat. Smears on a layer imported's 8000 grit diamond grinding paste. Takes wool felt following one direction dead dead presses live metal face exerts strength rubs.

Measures roughness's instrument probe slides across surface, Ra value drops to 0.02 micrometers below. Reaches SPI industrial standard's A2 level optical mirror face, transmits light rate percent of 98's polycarbonate hits out come just not will issue white.

Does full 8 work hours, surface can clear reflect out face on's sweat pores. Material purity as long as slightly lacks one thread, polishes polishes to last one step completely ruined. Percent of 0.02's sulfide clamped in naked eye sees not see's iron seam internal. High speed rotating's wool wheel one passes, surface immediately pops out diameter 0.01 millimeters' black color sand holes.

· Steelmaking furnace wants to pass through two times electro-slag remelting procedure purify exhaust impurities

· Flaw detector checks out internal has 0.2 millimeters' micro cracks immediately returns goods

· Grinding use's cloth wheel rotate speed highest rushes to per minute 6000 revolutions

Several ten thousands bucks' steel material has sand holes only can send go waste products station according to 7 dimes money one catty sell iron. Not issues problems' mold moves onto machine table, connects through 7 degrees' cold water pipes. Raw material heats to 290 degrees by high pressure squeezes into inner cavity. Mold surface hardness enough, carries live plastic melt flow every day two three ten thousands times' violent flushes washes.

One mold hits out 8 transparent lipstick outer shells, continuously does full 50 ten-thousands mold times, reflection face one point tiny scratch marks all not grow out come. Bumps into hardware market's black heart stalls takes several bucks money's domestically produced 420 stainless steel makes up number. Anti-corrosion performance barely deals with, polishing forever issues gray, like covered layer fog how also rubs not bright.

One Supplier

Bear Quality Responsibility

Buys one set 718H steel material's big chunk head injection mold, machine close mold force fixed at 250 tons. Workshop opens machine first hits 1000 ABS plastic outer shells tries tries water, results product side face pops out quite several paths shrinks water's deflated marks.

Looks for quite several factories gathers in together do work, shirk blame wrangle too common. Makes mold's boss complains injection machine table keep pressure not enough 80 megapascals, temperature also lacks 15 degrees Celsius. Injection factory's master vice versa says, mold base inside walks cooling water's small holes diameter only 6 millimeters, water flow slow to fundamentally scatters not away heat amount.

One family factory takes this order from head wraps to tail, situation just changes. Buyer not needs go manage eventually is who adjusts wrong water flow speed, receives order's factory must one person takes responsibility carries down come, honestly honestly hands out dimensions tolerance in positive negative 0.05 millimeters within's plastic finished product parts.

Factory manager takes every test link's do work indicators all distributes to workshop workers head on:

· First time tries mold, product completeness passes 85%.

· Mold cavity polishes roughness actual measure lower than 0.2 micrometers.

· Ejector pin hole single side leaves out's gap stuck in 0.008 millimeters within.

· Computer simulates injection time with real machine differences not reach 0.5 seconds.

Plastic part thickness marks 1.2 millimeters, 3D drawing face on pops out a 0.3 millimeters' sudden change small step, takes red pen draws a circle returns back draws drawing room. Slanted face draft angle's angle by forcedly changed to 2 degrees above, saves molding after demold hard pulls, takes plastic part surface scrapes flowers scraps.

Plans make 50 ten-thousands mold times' transparent PC lamp cover mold, purchase list white paper black words writes clear uses Sweden S136 vacuum quenched steel. Steel material pulls into factory building, quality inspector holding hand hold portable spectrometer measures contains chromium amount, numbers jumps pass 13% just allows moves into warehouse. Factory building must self bears not rusts not rots' quality bottom line.

Does work's machine table runs out come's data, compares prints red seal's guarantee book works use. CNC milling machine worker takes drawing file guides in go, cut cutter walks finish leaves down's allowance dead dead fixed at 0.1 millimeters. Fine carves procedure changes onto a handful diameter 0.5 millimeters' ball shape tungsten steel cutter, machine rotate speed pulls to per minute 24000 revolutions, continuously mills 16 hours all not stops rests.

Measures room does's is most wears people's picks thorns work. Zeiss three coordinate's ruby probe pastes curved face sweeps past go, grabs takes 300 coordinate points pieces forms curved face compare drawing. Measures out come dimension deviation big passes 0.015 millimeters' steel blocks, on duty group leader immediately lets line cuts machine tool re-cuts one piece mends on, one point tolerance all not leaves gives next one path procedure.

Mold down machine tool after, standing inspects' standards lists very clear:

· Steel material quenches hardness measures out come's deviation not reaches HRC 1.

· Up down mold fits' gap stuffs not in 0.01 millimeters' feeler gauge.

· Water path hits in 10 kilograms water pressure, holds 2 hours not leaks one drop water.

· Hot runner divides segments heats, control box temperature up down not reaches 2 degrees Celsius.

Fitter table's iron plate on, old master grabs a handful red lead powder smears on moving fixed mold parting face's four corners on. Close mold machine presses down 100 tons' strength takes mold closes tight, loosens open after looks red lead powder's marks, fits' area wants to occupies to 80% above. Color light not presses solid's place, master holding diamond small file knife little by little hand work grinds 2 hours.

Makes copper male electrode's discharge workshop arranges at two floor constant temperature room. Mitsubishi spark machine inputs does work's commands, discharges' gap numbers fixed at 0.015 millimeters. Spark not stopsly hits through insulates liquid, on P20 mold steel face on burns out VDI 3400 standard's 24 number fine skin textures, burns finish one whole group electrodes wants spends 18 hours.

Real machine onto materials tries tries whole set mold's mechanical hands feet flexible not flexible. One machine Haitian 280 tons servo injection machine loads full PA66 adds 30% glass fiber's materials, material barrel divides quite several segments heats to 280 degrees Celsius. Technician grasps stopwatch records down front 50 molds' time, mold opens closes to ejector pin springs out come's actions, steady steady proper proper stops at 18 seconds.

Buckle piece assembles' time finds plastic parts stuck gets has a little tight, exceeds 0.1 millimeters. Stations factory fitter half hour just takes mold pulls back maintenance area. Discharges machine table adjusts out original prior's coordinate positions, swings moves amount changes into 0.02 millimeters, faces buckle that one little little place discharges processes several micrometers, until two pieces plastic parts piece together comes strict seams matches seams.

Loads box onto vehicle before last checks one pass leaves factory data bills:

· Continuously opens 3 shifts, good products proportion stable at percent of 98.5 above.

· Dimensions full inspects calculates out come's Cpk process capability index big passes 1.33.

· Wooden boxes inside puts good 20 sets easily bad's spare ejector pins and springs.

· Hands over's U disk inside stores whole set molding parameters and walks water pipe drawing.

Signs contract white paper black words writes fixed 35 days delivers goods, late one day deducts tail money inside's thousand parts of five. One person wraps round's mold factory arranges shifts time, gives all CNC machine tools empties out percent of 20's spare use time. Processing center bumps onto breaks cutter or stops electricity inspects repairs, immediately changes one machine machine continues cuts, hides away hands not out come goods' huge amount fine tickets.

Outside iron frames on evenly sprays two layers green color anti-rust oil, wraps on three layers PE plastic films seals tight. Wooden box bottom under's pad woods on nails a vibration records sticker, records down ship on sea on floats 15 days' bumps forces. Receives goods factory inside's technician pries open wooden boards connects on water pipes, machine starts moves horse power runs up comes, one hour steadily presses out 200 plastic parts.

Craft Interconnect

Subcontracts out go does work, external's design company accords standard drawing library draws a chamfer R0.1 millimeters. Drawing throws gives outside's processing factory, machine tool master two hands one spreads, library inside smallest's tungsten steel cutter only has R0.2 millimeters, hard cuts just will scraps a piece good steel.

Own factory building inside hits through whole set does work's procedures, designer clicks mouse before just stares accurate workshop inside that machine Makino V33i machine tool. Adjusts out computer inside's cutters parameters table, smooth hand takes chamfer changes into R0.3 millimeters, matches workshop ready made's three flutes flat bottom cutter, spindle rotates speed sets fixed at per minute 18000 revolutions.

Drawing files sends to CNC programmer's screen on, walks cutter paths not uses again hits back re-audits. Computer knocks fixed opens rough leaves down 0.3 millimeters' allowance, fine processing walks cutter gaps sets dead at 0.05 millimeters. Cuts out come's H13 mold core steel blocks surface cutter marks even, worker pushes cart sends towards next one path procedure.

Heat treatment master receives hand this piece H13 steel, heart inside clear front head leaves how much spare meat. Sends enters vacuum quenches furnace, heats to 1020 degrees Celsius keeps warm two hours, outs furnace after hardness reaches HRC48 to 50. Steel material cools will shrinks thousand part of one, this pen account early just records on workshop's internal systems on.

Line cuts master clicks opens account book, slow walks wire machine tool cuts enters water holes time, hand moves towards outside offsets 0.015 millimeters. 0.2 millimeters thick's yellow copper wire threads passes 50 millimeters thick's steel plates, electric sparks takes quenches shrinks back go's dimensions exactly original seal not moves mends comes back. Up down procedures matches gets like is at one sheet table on eats meals.

Makes copper male electrodes and mold cores discharges' masters next to sits. Processing centers mills out come's purple copper electrodes, spark positions leaves 0.1 millimeters. Discharges master starts moves Sodick spark machine, rough hits uses 15 amperes' currents burns drops 0.08 millimeters, fine hits cuts to 3 amperes slowly repairs finishes left down's 0.02 millimeters allowances.

Two sides does works not uses hits phone checks accounts, drawings on's barcodes scans one down, spark machines' screens just pops out discharges gaps data. Factory inside several paths does works procedures takes dimensions little by little eats dead:

· Lathe turns outer circles leaves single side 0.2 millimeters, hands back head grinds machine grinds flat.

· Milling machine digs drops big pieces wastes steels, bottoms leaves 0.15 millimeters thicknesses prevents deforms.

· Quenches furnace burns finishes hardness pulls highs HRC15 points, dimensions shrinks 0.03 millimeters.

· Slow walks wire cuts holes carries on 0.03 millimeters compensates, threads yellow copper wires continuously cuts 3 cutters.

· Fitter takes 1000 grit sandpapers pushes polishes 2 hours, smears flats 0.005 millimeters' roughnesses.

Zeiss three coordinates hits points measures out come's tolerances biases 0.01 millimeters, data several seconds transmits gives polishes table. Polishes master changes onto 3 micrometers' diamond pastes, follows biases high's positions extra pushes 50 downs wool felts.

Deals with shrinks water rates' troubles also is at self home roofs eaves down digests finishes'. Makes car lamp covers uses' PC plastics, materials barrels temperatures pulls to 290 degrees Celsius, hits enters molds cools after's shrinks rates is thousand parts of five. Makes outer shells' factories self not has injections machines, only cares accords books on's dead boards numbers puts dimensions.

Wraps takes works' factories has self home's tries molds machines. Opens molds before, tries molds samples boards already on passes Haitian 160 tons injections machines. Head two molds hits out come's long strips shapes PC parts, takes verniers calipers cards live one measures, lengths 150 millimeters' edges shrinks 0.8 millimeters, actuals shrinks waters rates runs to thousand parts of five point three.

Tries molds personnel takes verniers calipers on's 0.8 millimeters errors knocks enters computers. Designs rooms receives messages, changes moves drawings files takes cavities lengths towards outsides expands 0.8 millimeters. Workshops re-arranges CNCs machines tools mends cutters processes, half days times just takes tolerances pulls backs drawings requires' ranges inside.

Bottom down this copies internals flows turns tables, records a sets cars centers controls consoles molds does works times' matches datas:

Master only cares faces internal issues down's work orders operates, no people towards outside pushes rotten accounts. Pays bills' boss not uses gives quite several factories hits phones mediates disputes. Drawings dimensions and machines tables cutters blades at factories buildings inside early just bites matches gets stricts stricts solids solids, plastics particles pours enters materials hoppers, presses out comes's just is tolerances not exceeds 0.05 millimeters' accurate goods.

Hidden Costs

Several families subcontracts factories pieces puts's quotes bills, totals numbers compares singles families wraps dries less writes 3 ten thousands bucks. Takes orders divides dispatches down goes runs on several months, flows waters sames spends out goes's wrongs moneys, finances personnels no ways writes enters fronts periods' budgets plans tables inside.

A pieces weighs reaches 450 kilograms' P20 molds bases steels plates, from Dongguans's steels materials shops sends towards Shenzhens's CNCs processes shops. Singles trips goods cars transports fees spends drops 600 bucks. Takes irons blocks makes on flats boards goods cars must moves uses 5 tons classes diesels forks cars, lines ups waits loads unloads consumes goes big half days. Comes returns tosses turns three trips, cars feet fees covers passes 2000 big oceans.

Receives orders wraps to bottoms' factories buildings inside, transfers this half tons heavys' irons lumps relies's is workshops ceilings boards ons' 10 tons classes travels cars. Irons hooks hangs firms steels plates fours circumferences's fours big hangs rings, workers presses down hands insides' remotes controls's buttons. Only passes 5 minutes, wholes pieces molds bases steadies steadies falls at nexts doors workshops' dragons gates mills machines tables faces ons.

Crosses factories communicates faces drawings mosts consumes minds spirits. Fours families factories's businesses personnels pulls ups a 50 peoples's WeChats groups. Mobiles phones screens throws outs a sheets marks dozens datas's CADs assembles drawings, purely is lines ups a strips 0.05 millimeters' tolerances lines, groups insides severals hundreds strips messages brushes down comes, threes days works days no's shadows.

Drawings modifies involves's capitals moneys calculates up comes scares peoples. Buys partys inspects 3Ds models, requires drawings adds a strips 0.8 millimeters wides' plastics prevents shrinks waters strips. Drawings files sends gives outsides processes shops, programs personnels knocks hits keyboards spends 4 hours re-writes machines tools codes. CNCs mills machines ons exactly cuts's a pairs tungstens steels cutters only cans forces actions stops scraps, materials materials fees losses ups thousands bucks.

Polishes shops and molds factories not at one buildings inside, masters inspects goods's rulers longs shorts not ones. Molds factories holdings verniers calipers measures outs lengths widths dimensions reaches standards, loads cars pulls goes outsides makes highs lights mirrors faces polishes. Outsides does works's masters uses wools felts pushes drops surfaces 0.02 millimeters' irons skins. Wholes sets irons blocks pulls backs injections machines one closes, plastics parts edges corners all pops outs hairs thorns wastes materials.

One families factories wraps takes alls works, does works's rules lists at workshops sames one faces walls ons:

· Draws drawings personnels advances early takes 0.02 millimeters' polishes losses calculates enters 3Ds models's irons blocks dimensions inside.

· Purchases departments drives comes's bigs trucks ones times natures pulls backs 3 tons H13 steels, singles sets molds spreads shares's transports fees not reaches 50 bucks.

· Qualities manages departments everys days mornings 8 o'clocks punctuals times issues threes dimensions hits points inspects bills, saves goes sames cities expresses deliveries sends papers qualities files's consumes times.

· Changes drawings commands throughs internals ERPs systems issues downs, halfs hours insides autos locks deads olds versions machines tools codes not allows cuts.

Electronics products lates a months places ons goods shelves outs sells, losses drops's is becomes hundreds ups thousands ten thousands's sells amounts. Fors divides clears bottoms to is which families smalls factories blocks lives coolings waters paths, threes families supplies merchants cans surrounds at machines tables besids pulls pulls halfs a months, shops inside's goods positions earlys lets others peoples occupies goes.

Pushes comes pushes goes drags slows does works progresses, reals machines tries produces pours in goes's plastics particles moneys follows towards ups flips. First families injections factories buys ordinarys ABS materials hits samples, whites blinds 20 kilograms plastics nots adjusts outs brights cleans surfaces. Changes one families understands trades situations's factories receives plates, workers holdings clears washes agents re-new clears washes injections machines materials barrels, whites whites throws drops 30 kilograms uses comes clears machines's wastes materials.

Alls wraps orders's factories workshops equips carries tries molds specials uses's removes humidities dries machines. Bakes materials irons boxes connects throughs 380 volts industrials electricities, controls cabinets takes airs humidities presses lows to 0.02% belows, continuous bakes plastics 4 hours. Injections engineers stares machines tables screens's pressures tables, feels outs mosts bests keeps pressures times fixed at 6.5 seconds, severals catties materials moneys justs cans fixeds goods ones wholes pages molds forms parameters tables.

Huges bigs's machines stops carries not does works just is at burns moneys. Outs sends cuts's parts takes backs comes repairs repairs changes changes, injections workshops that machine 2000 tons locks molds forces's larges types machines tables emptys turns carries waits molds bases sends comes assembles. Everys hours electrics tables walks words links togethers severals masters's workers wages consumes drops smalls severals hundreds bucks. Stops works delays threes days, ones ten thousands bucks opens spends transforms makes bubbles shadows.