When developing an electric toothbrush, the prototype phase directly determines whether the final product meets user expectations for comfort, Funktionalität, und Haltbarkeit. Unter allen Prototypenherstellungsmethoden, CNC -Bearbeitung stands out for its ability to handle the tiny, precise components of electric toothbrushes—but why is it the top choice for electric toothbrush prototypes? This article breaks down key aspects of CNC-machined electric toothbrush prototypes, vom Entwurf bis zum Test, to solve common R&D Herausforderungen.
1. Core Design Principles for CNC-Machined Electric Toothbrush Prototypes
A successful electric toothbrush prototype starts with design optimized for CNC capabilities. Below are four non-negotiable design focuses to ensure functionality and user-friendliness:
| Designaspekt | Schlüsselanforderungen | CNC-Kompatibilitätshinweis |
| Functional Precision | – Brush head-motor interface (exact fit to avoid vibration loss).- Button slots (aligned with circuit board triggers). | CNC’s ±0.05mm precision ensures motor and brush head coaxiality, reducing vibration noise. |
| Ergonomic Comfort | – Curved brush handle (Anpassungen 95% of adult hand sizes).- Anti-Rutsch-Muster (0.2mm depth for grip without discomfort). | CNC machines handle curves with consistent curvature (keine scharfen Kanten) and precise pattern depths. |
| Wasserdichte Zuverlässigkeit | – Dichtungsnuten (für Gummi-O-Ringe, IPX7-Standard).- Battery compartment threads (tight fit to prevent water ingress). | CNC cuts sealing grooves with ±0.02mm tolerance, ensuring O-rings form a perfect waterproof seal. |
| Machbarkeit der Montage | – Modulare Teile (brush handle, Batterieabdeckung, circuit board tray).- Snap-/Thread-Schnittstellen (simulate mass-production assembly). | CNC ensures assembly clearances of 0.1–0.3mm, enabling easy disassembly for maintenance tests. |
2. How Does CNC Machining Outperform Other Methods for Electric Toothbrush Prototypes?
Compared to 3D printing or silicone duplication, CNC machining addresses unique challenges of electric toothbrush prototypes (Z.B., tiny structures, Wasserdichtung). Hier ist ein direkter Vergleich:
| Vorteilskategorie | CNC-Bearbeitungsleistung | 3D Druckbeschränkung | Silicone Duplication Limitation |
| Precision for Tiny Parts | Button holes (φ3mm) with ±0.02mm tolerance.Motor shaft slots (coaxiality <0.05mm). | Typical tolerance of ±0.1–0.5mm (risk of button jamming or motor wobble). | Tolerance of ±0.2–0.5mm (poor for waterproof sealing). |
| Material Vielseitigkeit | Prozesse ABS (brush handle), PC (transparent battery cover), PMMA (viewing window), Und Aluminiumlegierung (Motorhalterung). | Beschränkt auf Kunststofffilamente (can’t replicate metal’s strength for motor parts). | Only uses epoxy/resin (keine Metallverträglichkeit; poor heat resistance). |
| Oberfläche & Functional Quality | Glatte Oberflächen (Ra0,8–Ra3,2) for grip comfort.Directly machines waterproof grooves (keine Nachbearbeitung erforderlich). | Noticeable layering (erfordert Schleifen; hard to achieve waterproof smoothness). | Smooth but limited detail (kann Anti-Rutsch-Muster nicht reproduzieren). |
| Funktionstests | Can assemble full prototype (Motor + circuit board) für vibration/waterproof tests. | Needs post-processing (Z.B., Bohrlöcher) to fit components; not ready for direct testing. | Only for appearance verification (no functional testing possible). |
3. Step-by-Step CNC Machining Process for Electric Toothbrush Prototypes
Die CNC-Bearbeitung folgt einer linearen Linie, repeatable workflow to ensure prototype consistency. Der Prozess hat 7 Schlüsselphasen:
- 3D Modelldesign & Optimierung
Verwenden Sie die CAD -Software (Solidworks / und) to design parts like the brush handle and battery compartment. Mark material (Z.B., ABS for handle), Präzision (± 0,05 mm), und Oberflächenbehandlung (Z.B., sandblasting for anti-slip).
- Materialauswahl & Cutting Preparation
Wählen Sie Materialien basierend auf der Funktion:
- Brush handle: ABS (vielseitig, Einfach zu maschine).
- Transparente Teile: PMMA (hohe Klarheit).
Wählen Sie Werkzeuge aus: φ1mm ball nose cutter for anti-slip patterns; φ5mm flat cutter for roughing.
- Werkzeugpfadprogrammierung
Generate G-codes for each part. Optimize paths to avoid tool interference (Z.B., for deep battery compartments, Verwenden Sie Schichtschnitt).
- Spannen & Knife Setting
Fix blanks to the CNC machine (vacuum adsorption for plastics; fixtures for metals). Use laser positioning to set the workpiece coordinate system (ensures machining accuracy).
- Grobe Bearbeitung
Entfernen 90% of excess material with large-diameter tools, A verlassen a 0.1–0,5 mm Aufmaß zum Abschluss. Saves time while protecting delicate structures.
- Fertig
Use high-speed cutting (8,000–12,000 rpm) to refine details:
- Brush handle: Add anti-slip patterns (0.2MM -Tiefe).
- Button slots: Machine to φ3mm ±0.02mm.
- Dichtungsnuten: Cut O-ring slots (depth 2mm ±0.02mm).
- Oberflächenbehandlung & Montageprüfung
- Oberflächenbehandlung: Sandblast the handle (anti-slip), polish PMMA parts (Klarheit), or plate metal brackets (Korrosionsbeständigkeit).
- Montage: Fit components (Motor, circuit board, O-Ringe) into the prototype.
- Testen: Benehmen vibration tests (check motor-brush head match) Und IPX7 waterproof tests (submerge in 1m water for 30 Minuten).
4. Materialauswahl & Key Testing for CNC-Machined Prototypes
Die Wahl des richtigen Materials wirkt sich direkt auf die Leistung des Prototyps aus. Below is a practical guide, plus must-perform tests:
Material Selection for Key Components
| Komponente | Empfohlenes Material | Key Performance Features |
| Brush Handle | ABS | Resistenz mit hoher Wirkung; easy to machine anti-slip patterns. |
| Transparent Battery Cover | PC | Tragenresistent; hohe Klarheit (to view battery level). |
| Motor Bracket | Aluminiumlegierung 6061 | Leicht; good heat dissipation for motor. |
| Waterproof Sealing Grooves | ABS + Rubber O-ring | ABS’s rigidity + O-ring’s flexibility = IPX7 waterproofing. |
| Viewing Window | PMMA | Hohe Transparenz; easy to machine to exact sizes. |
Must-Perform Functional Tests
| Testtyp | Zweck | Kriterien übergeben |
| Vibration Test | Verify motor-brush head match (avoid weak vibration or noise). | Vibration frequency 30,000–40,000 strokes/min; Lärm <60db. |
| Wasserdichtigkeitstest | Check if sealing meets IPX7 standards. | No water ingress after 30-minute submersion in 1m water. |
| Button Feel Test | Ensure press pressure and feedback match design (avoid too hard/soft). | Press pressure 150–250g; clear click feedback. |
| Assembly Test | Verify easy disassembly/assembly (for user maintenance). | Can remove battery cover in <10 Sekunden; no stuck parts. |
5. Yigu Technology’s Perspective on CNC Machined Electric Toothbrush Prototypes
Bei Yigu Technology, we believe CNC machining is the backbone of reliable electric toothbrush R&D. Its ±0.05mm precision solves two core pain points: tiny part alignment (Z.B., motor-button fit) and waterproof sealing—issues that 3D printing can’t address. Zum Beispiel, a client’s prototype used CNC-machined ABS handles with anti-slip patterns and PMMA windows: it passed IPX7 tests, had consistent vibration (35,000 Striche/min), and reduced R&Dzeit durch 30%. We recommend combining CNC (for critical parts like handles/motors) mit 3D -Druck (for non-functional decor) to balance cost and performance. Letztlich, CNC prototypes validate design flaws early, cutting mass-production risks.
FAQ
- What’s the cost range for a CNC-machined electric toothbrush prototype?
It ranges from 500 Zu 2,000 Yuan pro Einheit, Abhängig von der Komplexität (Z.B., 5-axis machining for curved handles costs more than 3-axis for simple parts). To reduce costs, use 3D printing for non-critical decor.
- How long does it take to make a CNC-machined electric toothbrush prototype?
Einfache Prototypen (basic handle + button) Nehmen Sie sich 5–7 Tage; Komplexe Designs (with motor brackets + waterproof grooves) take 10–14 days (including surface treatment and testing).
- Can CNC machining handle material shrinkage for plastic prototypes?
Yes—we account for shrinkage rates (Z.B., ABS ~0.5%) by reserving allowances during programming. Zum Beispiel, a 100mm ABS handle is machined to 100.5mm, so it shrinks to the exact 100mm after cooling.