When you choose Sunshar as your partner, you will get: Interactive quotes delivered in hours, not days. Quality consistent parts delivered in days, not weeks. A Free Manufacturability Analysis with every part design to save you time in the development process. A Lifetime Mold Guarantee for unlimited parts, No design restrictions. The part you designed is the part you’ll get.

Order Process
1.Send us the drawing with specifications for the quality, volume demand, mold life and others requirements.
2. Get a quote from us with part price, Mold costs and basis information.
3. Negotiation of the quality, price, material, delivery time, payment term and others.  
4. Confirm and place an order with first down payment.
5. We will have further analysis for your products from design to be manufacturing, and provide a qualified DFM report to you. To make sure there are no mistake before manufacturing.
6. Send mold design for customer double checking and approval. 
7. Order materials and begin to machining, update the manufacturing information once a week.
8. Assemble mold and have a regular full checking, then to try out for some first samples.
9. Self- inspecting and send the samples with our inspection report to customer for confirmation  
7.If the first sample comes out satisfied, the mold finished. If not, we will modify it until meeting customer’s requirements.  
8. Producing the qualitied parts and delivery of goods by sea or by air according to customer’s requirement.

FAQ
Q. When can I get the price?
A. We usually quote within 24 hours after we got your inquiry. If you are very urgent to get the price, please call us or tell us in your email so that we will regard your inquiry priority.
 
Q. How can I get the accurate price?
A. There are some basic specs we need to know for price calculate, they are: 3D drawings in Step/stp, IGS, X-T format are available, 2D drawings with tolerance or requirements, please suggest us your quantity too.
 
 Q. Do you accept the OEM?
 A. OEM is welcomed. We provide product customization service from your design. 
 
Q. What is the shipping?
 A: By express (FedEx, UPS, DHL, TNT, EMS, etc…), By Air or by sea.
 
Q. How do I pay for the order?
 A. The common payments are T/T (Telegraphic Transfer), western union, PayPal is also available.
 
Q. I have an idea for a new product, but don’t know if it can be manufactured. Can you help?
A. Yes! We are always happy to work with potential customers to evaluate the technical feasibility of your idea or design and we can advise on materials, tooling and likely set-up costs.
 
Q. What are the advantages to having my parts manufactured locally?
A. Sunshar can offer quick reaction times to any changes in specification, batch size or material. We can ship small or large quantities anywhere in Europe overnight to accommodate unforeseen changes in demand.
 
Q. My components have already been developed on CAD. Can you use the drawings?
A. Yes! DWG, DXF, IGS, SolidWorks, Pro/E, UG and Catita files can all be used to generate quotes, models and mould/tools – this can save time and money in producing your parts.
 
Q. Can I test my idea/component before committing to mould/tool manufacturing?
A. Yes, we can have the CAD drawings to make Computer simulation for designing and functional evaluations.
 
Q. What type of plastic is best for my design/component?
A. Materials selection depends on the application range and the environment situation in which it will function. We will be happy to discuss the alternatives and suggest the best material.
 
Q. What type of mould/tool do I need?
A. Mold/tools can be either single cavity (one part at a time) or multi-cavities (2,4, 8, 16 up to 64 parts at a time). Single cavity tools are generally used for small volume demand, up to 20,000 parts per year. And multi-cavities tools are for larger demands. We will according to your estimated annual volume demand and recommend the best solution for you.
 
Q. Ok, I’ve decided to go ahead with my project. How long will it take to get my parts?
A. It will take 3-8 weeks to have the mould/tool manufactured. It depends on the part’s size, construction complexity and the number of cavities (single or multi). After your final approval for the quality new tool, you can expect the parts delivered within 2-3 days.
 

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Designing Injection Molded Parts

Designing injection molded parts involves careful consideration of various parameters, including the wall thickness and draft angle. These factors are essential for a strong, durable part. Improper wall thickness can lead to sinking and warping defects. To avoid these issues, ensure that the walls of your injection-molded parts have a uniform thickness that does not vary too much from the rest of the part.

Designing out sharp corners in injection molded parts

When designing an injection molded part, it’s important to consider the corner radius. Sharp corners will create more stress, and this will lead to weak spots and cracks. Creating a radius around the corner helps distribute stress evenly and allows easier material flow and part ejection. Additionally, sharp corners in a mold can collect contaminants and create defects, including surface delamination.
Sharp corners in injection molded parts are a common source of stress and can cause the part to become damaged during the manufacturing process. In addition to trapping air, sharp corners may also lead to localized high temperatures that degrade the part. To reduce these risks, consider adding radii to all sharp corners.
Another important design factor to consider is wall thickness. Parts that have a smooth transition between sections should be designed with a minimum of five millimeters of wall thickness. Anything thicker will increase production cycle time and may also negatively impact mechanical properties. The use of fillets and chamfers can also help avoid these problems.
Designing out sharp corners in injection molded components can prevent costly problems from occurring during the manufacturing process. While the process is simple and straightforward, it needs to be done correctly to ensure quality. By following best practices, designers can ensure their parts won’t develop any problems or sink, warp, or voids. A poor design can also cause damage to the mold, which can cost thousands of dollars and hundreds of hours to redesign.
When designing injection molded parts, designers should consider the following guidelines. Incorporate internal and external radiuses. The internal radius (also called a fillet radius) is designed into the mold for improved quality and strength during the molding process. This radius is typically located on the inside corners or the bottom of a compartment. It can also be used for connecting walls and ribs. An external radius, on the other hand, is known as a round radius.
A right-angled part with sharp corners has a tendency to be loaded by pushing the vertical wall to the left. This creates a high-level of molded-in stress in the part. The resulting part may be weaker than expected because of the increased stress on the corner.

Importance of uniform wall thickness

Uniform wall thickness is a critical factor when designing injection-molded parts. This ensures that molten polymers can flow efficiently throughout the part. Additionally, it facilitates ideal processing. Varying wall thickness can cause problems during molding, such as air trapping, unbalanced filling, and weld lines. To ensure that your injection-molded parts are uniform, consult a plastic injection molding company that specializes in uniform wall thickness.
Injection-molded parts are more durable when the walls are uniform. A thin wall reduces the volume of material used in the part. However, thin walls can break during ejection. In addition, thin walls increase the possibility of voids. To prevent such problems, use larger machines that can produce parts with uniform wall thickness. This way, parts are easier to handle and ship.
Another important factor is the presence of gussets. These are support structures that stick out from a part’s surface. Gussets are useful for preventing warping, because they provide rigidity to thin unsupported sections. For this reason, gussets are essential when designing an injection-molded part.
Uniform wall thickness is especially critical in parts that have bends or rims. A uniform thickness helps maintain the mechanical strength and appearance of a part. However, this can be tricky as you may need to balance optical properties with mechanical ones. At Providence, we have the experience to help you navigate these challenges and produce quality parts.
Proper wall thickness is important for many reasons. It can affect both cost and production speed. The minimum wall thickness for injection molded parts depends on the part size, structural requirements, and flow behavior of the resin. Typically, injection molded parts have walls that are 2mm to 4mm thick. However, thin wall injection molding produces parts with walls as thin as 0.5mm. If you’re having trouble choosing the right wall thickness, consult an experienced injection molding company that can help you determine the appropriate wall thickness for your part.
Uneven wall thickness causes problems during injection molding. The uneven wall thickness may make the material flow through the part too quickly, or it may cause it to cool too slowly. This can lead to warping, twisting, or cracks. Even worse, uneven wall thickness can cause parts to become permanently damaged when they are ejected from the mold.

Importance of draft angle

Draft angles are an important part of design for injection molded parts. These angles are necessary because friction occurs on surfaces that come into contact with the mold during the molding process. A part with a simple geometry would only require a single degree of draft, but larger parts would need at least two degrees.
Almost all parts requiring injection molding will require some amount of draft. The better the draft, the less likely the parts will have a poor finish and may bend or break. Furthermore, parts with inadequate draft will take longer to cool, extending cycle times. Moreover, if the parts are too thick or have too little draft, they may become warped.
Having a draft angle in injection molding is very important, especially if the mold has sharp corners. Without it, parts will come out scratched and will shorten the life of the mold. In some cases, parts may even not be able to eject from the mold at all. To prevent this, air needs to be allowed to get between the plastic and metal. This allows air to escape and prevents warping during ejection.
The importance of draft angle is often overlooked in the design process. Adding this angle to the mold can help prevent problems with mold release and reduce production costs. A draft angle will also allow parts to release from the mold more easily and will lead to better cosmetic finishes and fewer rejected parts. Additionally, it will reduce the need for costly elaborate ejection setups.
Draft angle should be added to the design as early as possible. It’s crucial for the success of the injection molding process, so it is best to incorporate it early in the design process. Even 3D printed parts can benefit from this detail. The size of the draft angle is also important, especially for core surfaces.
A draft angle can be large or small. The larger the draft angle, the easier it is to release the mold after the mold is completed. However, if the draft angle is too small, it can lead to scrapes on the edges or large ejector pin marks. Draft angles that are too small can lead to cracks and increase mold expenses.

Cost

There are many factors that contribute to the cost of injection-molded parts, including the material used for the mold and the complexity of the design. For example, larger parts will require a larger injection mold, which will cost more to manufacture. Additionally, more complex parts may require a mold with special features. Mold makers can advise you on how to design your part in order to reduce the overall cost of an injection-molded part.
One of the biggest costs related to the production of injection molded parts is the cost of the tooling. Tooling costs can reach $1,000 or more, depending on the design, materials, and finishing options. Tooling costs are less if the part quantity is small and repeatable. Higher part volumes may require a new mold and tooling.
Injection-molded parts’ cost depends on the material used and the price of procuring the material. The type of material also influences how long the part will last. Plastics that contain high percentages of glass fibers are abrasive and can damage an injection mold. Therefore, they are more expensive but may not be necessary for certain applications. Additionally, the material’s thermal properties may also affect the cycle time.
Mold size is another factor that impacts the cost. Larger molds require more CNC machinery and building space than smaller molds. Additionally, the complexity of the part will also impact the cost. Injection molds with sharp corners and complex ribs will cost more than small injection molds without intricate designs.
Injection molding is a complex process that requires a variety of moving parts. During the process, a critical piece of equipment is the injection die. This machine is a large part of the process, and comes in different sizes and shapes. Its purpose is to accept the hot plastic and machine it to extremely precise tolerances.
If your project requires a complex product with a high degree of complexity, injection molding is an excellent choice. It is ideal for initial product development, crowdfunding campaigns, and on-demand production. Mold modifications can also lower the cost of injection molding.

editor by czh