OEM/ODM Services

Problem Description: Severe tool wear and excessive cutting temperatures occur when machining difficult-to-cut materials like titanium alloys and Inconel, leading to workpiece thermal deformation and surface quality deterioration in custom mold applications.

Solution:

Implement multi-layer coated carbide tools (TiAlN/AlCrN composite coatings) combined with high-pressure coolant systems and minimum quantity lubrication (MQL) for custom mold manufacturing. Optimize cutting parameters: reduce cutting speed to 80-120m/min, employ higher feed rates of 0.15-0.25mm/r, and minimize depth of cut to 0.5-1mm in custom mold machining processes.

Execute layered cutting strategy with intermediate stress relief annealing between layers for custom mold components. Establish tool wear prediction models through spindle power monitoring and vibration signal analysis for real-time tool condition monitoring during custom mold production.

Deploy high-pressure coolant systems (≥70bar pressure) ensuring adequate cooling in cutting zones of custom mold workpieces. Utilize adaptive machining sequences with thermal compensation algorithms for custom mold precision requirements.

Through process optimization, tool life can be extended by 60-80%, surface roughness controlled within Ra0.8μm, while minimizing thermal distortion effects on dimensional accuracy in custom mold manufacturing applications.

Problem Description: Thin-wall components are susceptible to chatter during machining, resulting in poor surface quality, low dimensional accuracy, and potential part rejection in custom mold manufacturing.

Solution:

Deploy variable helix angle end mills with unequal tooth spacing to reduce periodic cutting force fluctuations during custom mold machining. Implement adaptive control strategies using accelerometer-based real-time vibration monitoring with dynamic spindle speed and feed rate adjustments for custom mold precision requirements.

Design specialized vacuum fixture systems providing uniform support distribution to enhance workpiece rigidity in custom mold production. Execute multi-pass milling strategies with single-pass depths limited to 0.2-0.5mm using smaller diameter tools (φ6-12mm) to minimize cutting forces during custom mold fabrication.

Integrate active damping systems providing counter-vibration compensation at critical frequency ranges for custom mold operations. Conduct modal analysis to determine optimal cutting parameter windows avoiding resonance frequencies in custom mold manufacturing processes.

Combine with high-speed machining technology, elevating spindle speeds to 15000-25000rpm for light-load, high-efficiency cutting of custom mold components. This solution achieves thin-wall thickness tolerances within ±0.02mm and surface roughness of Ra0.4μm while maintaining structural integrity throughout the custom mold machining process.

Problem Description: During multi-material co-injection processes involving TPE/PP, PC/ABS combinations, insufficient interfacial bonding strength between different materials leads to delamination and product failure in custom mold applications.

Solution:

Implement compatibilization technology using maleic anhydride grafted polypropylene (PP-g-MAH) compatibilizers to enhance interfacial bonding in custom mold manufacturing. Optimize injection molding parameters: set first material injection temperature at melting point +40-60°C, maintain first material temperature at Tg+20-30°C during second material injection to ensure effective molecular diffusion for custom mold operations.

Execute sequential injection strategy with first material injected to 85-90% cavity volume, hold pressure for 1-2 seconds to form semi-solidified layer, then immediately inject second material in custom mold processes. Design dedicated hot runner systems ensuring material changeover time within 2-3 seconds for efficient custom mold production.

Incorporate micro-texture structures in custom mold design to enhance mechanical interlocking effects. Apply surface treatments including plasma treatment or chemical etching to strengthen interfacial bonding in custom mold applications. Implement online quality monitoring through injection pressure curve analysis to assess interfacial bonding quality during custom mold operations.

This solution achieves interfacial bonding strength reaching 80-90% of base material strength, effectively preventing delamination phenomena while maintaining production efficiency and dimensional accuracy requirements for custom mold manufacturing processes.

Problem Description: Workpieces exceeding 100mm thickness experience reduced machining accuracy and deteriorated surface quality due to non-uniform discharge gaps and inadequate dielectric circulation during wire cutting in custom mold manufacturing.

Solution:

Implement large taper compensation technology with pre-set 0.02-0.05° taper angles to compensate gap variations in thick sections of custom mold components. Optimize pulse power parameters using layered discharge strategy: upper section employs high current/long pulse width (Ip=8-12A, Ton=25-40μs), lower section utilizes low current/short pulse width (Ip=4-6A, Ton=8-15μs) for custom mold precision requirements.

Design dedicated flushing systems with upper/lower nozzle pressures set at 0.15-0.25MPa ensuring adequate dielectric circulation throughout thick sections of custom mold workpieces. Apply variable frequency wire feeding technology with real-time wire tension adjustment (10-15N) and wire speed control based on discharge conditions in custom mold manufacturing processes.

Execute multi-pass cutting strategy: rough-semi-finish-finish cuts with material allowances of 0.15mm, 0.05mm, and 0.02mm respectively for custom mold accuracy. Install auxiliary flushing holes at thick section mid-points improving chip evacuation during custom mold production.

Utilize high-conductivity electrode wire (φ0.18-0.25mm molybdenum wire) enhancing discharge stability in custom mold fabrication. Through process optimization, thick section workpiece accuracy achieves ±0.01mm tolerance with surface roughness within Ra1.6μm specifications for custom mold applications.