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射出成形による自動車用アームレストベースの製造

製造工程	プラスチック射出成形サービス & プラスチック金型製作サービス & Foam Injection Molding
部品材料	ABS + PC
金型タイプ	ラピッド・ツーリング
応用産業	自動車
表面処理	Foaming & Leather Covering
公差（精度）	部品：±0.1mm(±0.004″) 金型：±0.05mm(±0.002″)

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よくある質問

The design of this car armrest base is relatively complex. The structural features of the product include: the internal structure of the armrest base is quite intricate, containing multiple undercuts, and some of the clip positions have certain angles. These design elements increase the difficulty of mold design and manufacturing. The raw part has low aesthetic requirements since it will undergo foaming and leather covering processes afterward.

Customer Requirements For Automotive Armrest Bases Production

Our customer has strict requirements for the product’s functionality and production efficiency:

Functionality Requirements: The product needs to have good structural stability and assembly precision to ensure its functionality during use.

Quantity Requirements: As the product is made using rapid tooling, the quantity required is not high, with the primary focus on achieving its functionality.

Solutions to Manufacturing Challenges of Car Armrest Bases

Rapid Mold Design:

For the parts with significant undercuts and angles, we designed multiple sliders そして インサート to ensure the perfect formation of all details.
During the design process, special attention was given to the design of the joint areas. By optimizing the gate location and cooling system, we reduced the sink mark issues at the joint areas during injection molding.

High Precision Processing:

We use high-precision CNC machining technique to ensure the dimensional accuracy of every part of the mold.
The mold undergoes meticulous treatment to ensure high precision of the product structure, meeting the customer’s functionality requirements.

Rapid Tooling Manufacturing:

Given the customer’s low quantity requirement, we adopted rapid tooling manufacturing technology, which meets the customer’s time requirements while ensuring high product quality.
By optimizing injection molding parameters such as injection pressure, speed, and holding time, we further control the dimensional accuracy and surface quality of the product.

Product design of automotive armset base

Functionality Standards

1. Structural Stability:

The customer requires that the product maintain a high degree of structural stability during use, avoiding any deformation or loosening.
Acceptance involves mechanical tests such as pressure tests and torsion tests, ensuring the product withstands up to 1000 N of force without structural failure.

2. Assembly Precision:

The product must have high assembly precision, with all clips and mounting holes perfectly matching other components.
During acceptance, assembly tests will be conducted to ensure the armrest base fits seamlessly with other parts, with tolerances within ±0.1 mm.

3. Function Realization:

The armrest base must perform all its designed functions, such as support and storage, in various usage scenarios.
Acceptance includes simulating different real-life scenarios to verify the product’s functionality, ensuring it can handle weights up to 5 kg without performance degradation.

Injection Molding Defect Standards

1. Sink Mark Control:

There should be no noticeable シンク跡 in critical areas such as joints and key structural points, ensuring the integrity of the appearance and structure.
Acceptance involves visual inspection and measurement tools to ensure shrinkage does not exceed 0.5% in these areas.

2. Surface Defects:

The product surface must be smooth and flat, free of visible フローマーク, 溶接線, 泡, and other 射出成形の欠陥.
Acceptance includes detailed surface inspections, ensuring defect-free surfaces with a roughness average (Ra) less than 1.6 µm.

3. Dimensional Accuracy:

All design dimensions must be within specified tolerances, especially critical assembly positions and functional areas.
Acceptance involves using precision measurement equipment to verify dimensions, ensuring they fall within a tolerance range of ±0.2 mm.

4. Warpage and Deformation:

The product must not exhibit warpage or deformation, maintaining the designed shape and angles.
Acceptance involves flatness and shape checks, ensuring warpage does not exceed 1 mm per 100 mm.

Q1. How do you ensure the durability and strength of the car armrest base during the injection molding process?

素材の選択: High-strength, impact-resistant materials such as ABS or PC+ABS ensure durability and strength.

金型設計: Precise mold design with uniform wall thickness and well-placed ribs increases structural strength.

プロセス制御: Control injection parameters (pressure, speed, holding time) to ensure material density and strength. Optimize cooling system design to ensure uniform cooling and reduce internal stress.

Quality Testing: Rigorous quality tests (mechanical, durability, structural stability) ensure the product meets strength standards.

Q2. How do you produce car interior parts with complex geometries through injection molding?

Precise Mold Design:

Use multiple sliders and inserts to form complex shapes and internal structures.
Optimize gate location and venting system using advanced mold flow analysis software.

High-Precision Machining:

Use high-precision CNC machining to ensure mold accuracy.

Optimized Process Parameters:

Adjust injection speed, pressure, and holding time to ensure material fills the mold cavity evenly.
Control cooling time and temperature to maintain stable shape and dimensions.

Multiple Trial Runs and Adjustments:

Conduct multiple trial runs and adjustments to optimize process parameters and mold design.

Q3. What is the manufacturing cost of the car armrest base at First Mold?

Material Cost: High-quality materials like ABS or PC+ABS have higher costs but ensure quality and performance.

金型費用: Complex structures require high-precision CNC machining and multiple trial runs, increasing mold costs.

Process Cost: Advanced injection molding equipment and precise process control add to the costs.

Production Quantity: Low production quantities due to rapid tooling result in higher per-unit costs.

Q4. What materials are typically used for car armrest bases, and why?

PC+ABS Material:

メリット: Combines PC’s rigidity and heat resistance with ABS’s processability and finish.
申し込み: Used for higher mechanical performance and aesthetic requirements.