PC PPS Honeycomb Mold Case Study

Mold Design for Dual-Material Honeycomb Frame

This project presented a unique engineering challenge: designing a large-format honeycomb panel mold with intricate through-holes and tight dimensional tolerances. The dual-material requirement—anti-static PC and PPS—added further complexity due to their differing shrinkage rates and processing characteristics.

To ensure consistent part quality, we developed two dedicated hot runner systems, each calibrated to the specific flow behavior of the chosen material. A multi-point valve gate configuration allowed for uniform filling and minimized weld lines. We also implemented a highly efficient conformal cooling system to maintain thermal stability across the mold surface, preventing warpage and ensuring repeatable accuracy.

Mold Design for Dual-Material Handle

The handle components, while smaller in size, demanded exceptional precision. Their mirrored design and role in structural assembly required a tight tolerance on every detail. To meet this, we engineered a 1+1 parallel mold with solid steel construction, allowing both left and right handles to be molded simultaneously with identical performance.

Custom steel inserts and a guided ejection system helped maintain part integrity and ensure smooth release. Shrinkage differentials between PC and PPS were carefully compensated for, enabling seamless fit and function during downstream assembly.

Engineering Solutions for Stable Mass Production

Material-Specific Molding Characteristics

• Anti-static PC: Known for its impact resistance and visual clarity, PC is sensitive to temperature variation. We implemented balanced thermal zoning and carefully routed water lines to maintain optimal cavity temperatures.

• PPS: A high-performance, glass-fiber reinforced thermoplastic with low shrinkage and high stiffness. Due to its high processing temperature and abrasive nature, we used hardened cavity steel and fine venting to preserve tool life and ensure complete fills.

Mold Manufacturing Precision

• Tailored shrinkage compensation for both PC and PPS

• Gate locations refined using Moldflow simulations to ensure uniform pressure distribution

• Geometry-specific cooling channel design for faster, more consistent cycle times

• High-polish finishes and DLC coatings in high-wear zones to extend mold longevity

• Comprehensive T0/T1 validation to confirm production readiness

Component Mold Design Highlights

Honeycomb Frame Molds

• Built for structural stability over a large surface area

• Engineered multi-point injection to balance material flow

• Optimized cooling system and core polishing to reduce warpage and maintain flatness

Handle Molds

• Dual-cavity design enabled mirrored parts with exact symmetry

• Tight-tolerance machining of alignment features to support precise assembly

• Streamlined ejection and compact layout for robust production performance

Project Implementation

We handled the project from start to finish, covering CAD design, CNC roughing and finishing, EDM work, bench assembly, and final integration of the hot runner system. Throughout each phase, our team maintained strict quality control to ensure dimensional accuracy and superior surface finish.

Technical Milestones

• Moldflow analysis confirmed balanced filling and optimal gate placement for both materials

• All four molds were delivered on time and passed validation after initial sampling

• Dimensional checks confirmed compliance with client specifications across all parts

• The customer approved the samples, noting excellent fit, finish, and assembly performance

Our Commitment: Proven Precision in Complex Molding

At Guangdian Mould, we bring deep expertise to every tooling project—especially those involving dual-material parts and demanding geometries. Our commitment is simple: to deliver reliable, production-ready molds that perform from day one, with no rework required.

For technical consultation or project support, please contact our project manager, Mr. Peng Ting. We're ready to assist from concept to completion.