News and Updates - Nano mould release, Nano mold release
 
   
 


Project:           Chip choke coil for a Japanese MNC
Usage:             Used in LCD panels, mobile phone and other electronics component
Mold material:  Aluminum
                                                                                                                                          
Problems: Customer is molding electronic component in the production line.
All molds are required to be oven baked at 200 degree C for 20mins.
The main problem is due to the epoxy content that overflow and hardened inside the cavities,
Mold release agents are not allow to be used to avoid contamination on the substrate.
The buildup is extremely difficult to remove after molding.

                                                                            
Before using Nanomouldrelease coating, the overall rejects is 3.5%~4%
Production is slow, as after every few cycles require the production operator to scrub and clean away the epoxy residue before the next molding process. Extra molds are made in order to maintain the daily production targets.
Molding cost is very high, as new molds are replaced every 3-5 months due to the excessive buildup that was beyond repaired.

After coating with Nanomouldrelease,
Total rejects is reduce down to 0.2%~0.3%.
Productivity up by 10~15%
Existing molds are re-coated and re-used every 6-8 weeks
No records of new molds made so far after coated.

mold release

600pcs of mold have been coated with Nanomouldrelease.



Project:             Military
Usage:              M16, 5.56 rounds Plastic Bullet Blanks
Material:           66% glass filled
Mold material:    STAVAX


               


Problems: Customer molding plastic bullet blanks in a 32 cavity mold, using special formulated resins with 66% glass filled content material.
The inserts were Titanium coated to improve the wear resistance caused by the abrasiveness from the resin.
But despite to the preventive measures, it still didn't last long after 40-50K cycles where the coating starts to chip and flake.
Huge rejects of deformed and bulging parts around the profile area.
In worst scenario, the whole mold is required to be stripped down in order to abstract the stuck parts.


             


Before using Nanomouldrelease coating, reject rate are running very high at 6-7% with the aid of mold release agents every 4-5 cycles. Expensive titanium coating inserts are required to monitor closely for chipping, and extra new inserts are fabricated to replace worn out ones due to tight dimensional integrity. Only 2 million pieces are produce in a month.


After coating with Nanomouldrelease, customer achieved uninterrupted molding of 50,000 cycles = 1.5 million pieces within 2 weeks without any aid of mold release agents. Huge saving are recovered as overall reject were down to 0.4 percent.
Fewer inserts are made due to regular mandatory maintenance every 2 weeks.
The company profited instead of losing money in this project.

 
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