In the manufacturing of New Energy Vehicle (NEV) motors, flawlessly integrating multiple metal laminations (inserts) with high-performance engineering plastics remains a significant challenge. Traditional injection molding processes often lead to plastic overflow, known as flash , due to the cumulative tolerance of the metal stacks. Furthermore, improper slider engagement can scratch the delicate metal parts . These defects severely compromise motor performance and longevity.
To overcome these issues, we have developed the "In-Mold Spring-Loaded Insert" Technology . This solution represents a groundbreaking innovation in mold design. Its ingenious elastic structure dynamically compensates for tolerance variations in the iron sheets during injection, fundamentally preventing issues like flash, excess plastic, and slider damage, ensuring every single product is flawless.
Ultimate Tolerance Control：The product integrates N pieces of 0.2mm ultra-thin iron sheets. Through hot-pressing and our patented mold technology, the cumulative tolerance is strictly controlled within +/- 0.5mm, meeting the most demanding motor assembly requirements .
High-Performance Material Application： We use PA66+GF15 material, which offers superior mechanical strength, dimensional stability, and excellent heat resistance compared to standard engineering plastics, ensuring the stator's long-term stable operation under harsh conditions .
Optimized Product Structure：With dimensions of ￠87x67mm, the unique undercut design around the product ensures a secure and reliable assembly with other components .
The Strength from T3 Trials to Mass Production：Our promises are backed by proven results. The mold for this product successfully advanced to mass production right after the T3 trial stage and has since been continuously and successfully applied to various stator and rotor series molds for renowned automotive brands like Audi . This not only demonstrates the maturity and efficiency of our solution but also highlights our strength as a one-stop molding solution expert .
Take Action Now for Your Custom Solution!
If you are seeking a solution for precision injection molding challenges in NEV components, contact us today. We offer a complimentary DFM analysis and technical consultation.
📧 Email: [email protected]
🌐 Website: www.molds-maker.com
