Nitrogen Injection Tooling

Network Host Controller Panel: Advanced Manufacturing with Nitrogen Assisted Injection Tooling

Part Specifications:

• Part Name: Network Host Controller Panel

• Material: ABS+PC (High-strength thermoplastic blend)

• Mold Configuration:

• Mold Type: 1-Cavity

• Core & Cavity Steel: 1.2718H (Premium hot-work tool steel for high wear resistance)

• Mold Base: LKM Standard (DME-compatible)

• Gating System: Cold runner with precision point gate

• Tolerance: ±0.5mm (Critical for flatness requirements)

Key Manufacturing Process:
This component utilizes Nitrogen Assisted Injection Tooling to achieve:
✔ Ultra-thin wall consistency (0.8-1.2mm typical)
✔ Absolute flatness ≤0.3mm/m²
✔ Zero visible shrinkage marks

Technical Highlights:

1. Nitrogen Assisted Injection Tooling Implementation

• Gas Pressure: 150-300 bar nitrogen injection

• Timing Sequence: Precisely synchronized with plastic injection phase

• Benefits vs Conventional Molding:

• 40% reduction in cooling time

• Eliminates sink marks on large flat surfaces

• Improves dimensional stability for tight-tolerance parts

2. Multi-Process Compatibility

• Insert Molding:

• Metal EMI shields or connectors can be embedded

• Pre-insert temperature control to prevent thermal stress

• Overmolding:

• Secondary soft-touch TPE layers possible

• Bonding strength >8N/mm²

• PVC Injection Molding Alternative:

• For flame-retardant versions (UL94 V-0 compliant)

• Requires specialized corrosion-resistant mold coatings

Quality Assurance Features:
▸ Mold flow analysis prior to tool fabrication
▸ In-mold sensors for pressure/temperature monitoring
▸ Post-molding CMM verification of flatness
▸ 100% visual inspection for surface defects

Production Considerations:

• Cycle Time: 28-35 seconds (varies with wall thickness)

• Annual Capacity: ~250,000 pieces with single-cavity tool

• Tool Maintenance:

• Monthly nitrogen valve inspection

• Biannual mold surface refurbishment

Industry Applications:
◉ 5G network equipment enclosures
◉ Industrial IoT control panels
◉ Automotive infotainment systems
◉ Medical device housings

This manufacturing approach combines plastic injection efficiency with Nitrogen Assisted Injection Tooling precision to produce high-specification technical components. The process is equally effective for insert molding of hybrid structures or overmolding for enhanced ergonomics. For cost-sensitive applications, PVC injection molding variants can be developed using compatible material formulations.