Key Takeaways
- Pain Point Solved: High defect rates (≥5%) from sinks, flash, or bubbles, leading to rework.
- Core Value: Lower defect rates to ≤0.5%, meeting automotive IATF 16949 standards.
Step-by-Step Implementation
1. Eliminate Sink Marks: Standardize Wall Thickness
- Root Cause: Wall thickness differences >2mm (e.g., 3mm → 1mm) cause uneven resin shrinkage.
- Fix: Heya’s mold design caps thickness variation at 0.5mm, paired with ±0.01mm machining precision to eliminate sinks.
2. Stop Flash: Ensure Tight Cavity-Core Alignment
- Mistake to Avoid: Over-reliance on clamping force (wears down molds).
- Permanent Solution: Heya’s "dual-locating pin" design achieves ≤0.005mm cavity-core alignment—no excess clamping needed.
3. Banish Bubbles: Pre-Dry Resins Properly
- Critical Standard: PC/PMMA resins need moisture content ≤0.02%.
- Heya Process: 3-stage drying (preheat → dehumidify → insulate) reduces bubble rates from 3% to 0.
4. Prevent Warpage: Customize Cooling for Large Parts
- Case Study: 300mm-long automotive DRL strips warped >1mm with traditional cooling.
- Heya Fix: Segmented cooling channels (1 independent zone per 100mm) controls warpage to ≤0.3mm.