Our Polycarbonate PC Injection Molding Services

Eleve su producción de alto rendimiento con la prima de Yigu Technology Policarbonato (ordenador personal) Injection Molding services—where clarity meets durability. Aprovechando nuestra experiencia de moldeo por inyección, maquinaria avanzada, y herramientas personalizadas, we deliver precision-molded PC parts that excel in impact resistance, tolerancia al calor, and transparency—perfect for automotive, Electrónica de consumo, dispositivos médicos, and optical applications demanding uncompromising quality.​

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¿Qué es el policarbonato? (ordenador personal) Moldura de inyección?

Policarbonato (ordenador personal) is a high-performance thermoplastic polymer renowned for its exceptional balance of strength, claridad, y resistencia al calor. Derived from bisphenol A (BPA) and phosgene (or BPA-free alternatives), PC’s unique molecular structure (aromatic carbonate links) gives it properties that outperform most other transparent plastics. Moldura de inyección is a manufacturing process that melts PC pellets, inyecta el material fundido en una cavidad de moho personalizado, lo enfría para solidificar, y expulsa la parte terminada. Juntos, Moldeo por inyección de PC produce robusto, transparente (or opaque) components that thrive in demanding environments—from shatterproof eyeglass lenses to heat-resistant automotive headlights.​

Definiciones clave & Conceptos centrales

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Material Properties of PC​

PC’s unique properties make it the top choice for applications requiring both strength and clarity:​

• Alta resistencia al impacto: Notched Izod impact strength of 60–80 kJ/m²—20x stronger than glass, 10x stronger than acrylic, and shatterproof (even when struck hard).​

• Clarity & Transparencia: 90% transmitancia de luz (VS. acrylic’s 92%—negligible difference) with low haze (≤1%), making it ideal for optical applications.​

• Resistencia al calor: Temperatura de uso continuo (CORTAR) of 120–140°C; can withstand short-term exposure to 180°C (P.EJ., automotive engine bay heat or medical sterilization).​

• Estabilidad dimensional: Bajo coeficiente de expansión térmica (Cte: 6.7–7.0 × 10⁻⁵/°C)—retains shape even when exposed to temperature fluctuations (critical for precision parts like optical lenses).​

Resistencia química: Resistente a los aceites, grasas, y la mayoría de los productos químicos para el hogar (except strong acids/bases like sulfuric acid or ammonia).

Nuestras capacidades: Delivering High-Performance PC Injection Molding

En la tecnología yigu, we specialize in PC injection molding—our capabilities are tailored to handle PC’s unique processing challenges (punto de fusión alto, sensibilidad a la humedad, viscosity) and deliver parts that meet the strictest industry standards (P.EJ., FDA para dispositivos médicos, ISO 10366 for optical components).​

Desglose de capacidades centrales

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The PC Injection Molding Process: Precisión paso a paso

PC’s unique characteristics—high melting point, sensibilidad a la humedad, y alta viscosidad: solicite un especializado, optimized process to maintain clarity, fortaleza, y estabilidad dimensional. Nuestro flujo de trabajo minimiza los defectos y maximiza el rendimiento, si estás produciendo 50 optical lens prototypes or 500,000 smartphone casings.​

Paso 1: Preparación de material (Critical for PC)​

PC absorbs moisture rapidly (arriba a 0.3% of its weight in 24 horas a 50% humedad), Que causa hydrolytic degradation (amarillento, burbujas, or reduced impact strength) during molding. Nuestro proceso de preparación elimina este riesgo:​

• El secado: PC pellets are dried in dehumidifying dryers at 120–140°C for 4–6 hours (BPA-free PC: 120° C/4hrs; glass-filled PC: 130°C/5hrs; optical PC: 140° C/6hrs) para reducir el contenido de humedad a <0.02%.​

• Mezcla de aditivos/relleno: Mezclar pellets secos con aditivos (Estabilizadores UV para uso al aire libre, Retardantes de la llama para la electrónica) o relleno (fibra de vidrio para fuerza adicional, carbon fiber for conductivity—note: fillers reduce clarity).​

• Almacenamiento: Dried pellets are stored in sealed, heated hoppers (60–80 ° C) to prevent reabsorbing moisture before molding.​

Paso 2: Diseño de moldes (Optimized for PC)​

PC’s high viscosity (10x higher than PP) and low shrinkage (0.5–0.8%) require mold designs that prioritize flow and precision:​

• Flow Optimization: Molds include large runners (1.5–2x the size of ABS molds) and wide gates to help PC flow into complex cavities (P.EJ., thin-walled electronics casings).​

• Sistemas de enfriamiento: Uniform water-cooling channels (spaced 20–30mm apart) to prevent uneven cooling (which causes warping or cloudiness); mold temperature maintained at 80–120°C (más alto que la mayoría de los plásticos) to reduce internal stress.​

• Optical Considerations: Molds for optical PC parts (lentes, prisms) have mirror-polished surfaces (Real academia de bellas artes <0.02 μm) and no parting lines (to avoid light scattering); use of hot runner systems to prevent material degradation in cold runners.​

Paso 3: Parámetros de inyección (Tailored to PC Grades)​

PC’s high melting point and viscosity require precise parameter tuning to avoid degradation (amarillento) o relleno incompleto. A continuación se muestran configuraciones estándar para dos calificaciones comunes:​

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Paso 4: Operaciones posteriores al moldeo

Después de demoldar, PC parts may undergo:​

• Guarnición: Eliminación de flash (exceso de plástico) with diamond-coated tools (to avoid scratching PC’s surface—critical for optical parts).​

• Recocido: Heating parts to 110–130°C for 1–2 hours, Luego se enfría lentamente (5–10°C/hour) Para reducir el estrés interno (prevents cracking in high-temperature applications like automotive headlights).​

• Tratamiento superficial: Aplicando recubrimientos, textura, o impresión (Ver sección 5 para más detalles).​

• Inspección: QC checks for:​

• Clarity: Haze measurement (≤1% for optical parts) and light transmittance (≥88% for clear parts).​

• Precisión dimensional: Laser measurement (±0.001mm for optical parts).​

Resistencia al impacto: Notched Izod testing (≥60 kJ/m² for general-purpose PC).

Materiales: Choosing the Right PC Grade for Your Project

Not all PC is the same—each grade is tailored to specific applications, balancing clarity, fortaleza, y costo. Seleccionar la calificación correcta asegura que sus piezas cumplan con el rendimiento, regulador, and design goals.​

Common PC Types for Injection Molding​

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Material Selection Tips​

1. Prioritize clarity vs. fortaleza: For optical applications (lentes), choose optical-grade PC; para piezas estructurales (soportes automotrices), pick glass-filled PC (trade clarity for strength).​

2. Check regulatory needs: For food/medical contact, use BPA-free PC (se encuentra con la FDA 21 CFR 177.1580); para la electrónica, use flame-retardant PC (se encuentra con UL94 V0).​

Abrazar la sostenibilidad: Our rPC is ideal for brands focused on eco-friendly practices—use it for opaque, partes no críticas (P.EJ., colored smartphone cases) to cut costs and reduce environmental impact.

Tratamiento superficial: Enhancing PC’s Function & Estética

PC’s smooth, clear surface is ideal for customization—but requires specialized treatments to avoid scratching or reducing clarity. We offer five core treatments tailored to PC’s properties:​

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Ventajas: Why Choose PC Injection Molding?

PC injection molding offers unmatched benefits for applications requiring a blend of strength, claridad, and heat resistance—outperforming most other transparent plastics and even glass in many cases.​

Key Advantages of PC Injection Molding​

• Alta resistencia al impacto: 20x stronger than glass and 10x stronger than acrylic—PC parts are shatterproof (P.EJ., a PC water bottle won’t break if dropped, unlike glass or acrylic).​

• Clarity & Transparencia: 90% transmitancia de luz (nearly as clear as glass) with the flexibility of plastic—ideal for optical applications (lentes) y productos de consumo (trampas transparentes).​

• Resistencia al calor: Continuous use temperature of 120–140°C (acrylic maxes out at 80°C)—works in high-temperature environments like automotive engine bays or medical sterilization (short-term exposure to 180°C).​

• Estabilidad dimensional: Baja expansión térmica (6.7 × 10⁻⁵/°C) VS. acrílico (17 × 10⁻⁵/°C)—PC parts retain shape in temperature fluctuations (critical for precision parts like optical lenses).​

• Personalización: Accepts additives (UV/flame retardants), relleno (fibra de vidrio), y tratamientos superficiales (hard-coat, impresión)—adapts to any application, from opaque structural parts to ultra-clear optics.​

PC VS. Other Transparent Injection Molding Plastics​

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Industria de aplicaciones: Where PC Injection Molding Excels

PC versatility—blending strength, claridad, and heat resistance—makes it indispensable in five key industries. A continuación se presentan casos de uso del mundo real y nuestras soluciones a medida:​

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Estudios de caso: Our PC Injection Molding Success Stories

We’ve helped clients across industries solve complex challenges with PC injection molding—delivering parts that meet strict standards for clarity, fortaleza, y rendimiento. Below are three standout projects:​

Estudio de caso 1: Optical-Grade PC Automotive Headlight Lenses​

• Desafío: Un fabricante automotriz líder necesitaba 300,000 headlight lenses that were ultra-clear (≥90% light transmittance), inastillable (Para cumplir con los estándares de seguridad), and resistant to yellowing (para 5+ Años de uso al aire libre). Their previous acrylic lenses cracked easily and yellowed after 2 años.

• Solución: Usamos optical-grade PC (92% transmitancia) and designed custom hardened steel molds with mirror-polished cavities (Real academia de bellas artes 0.02 μm) to ensure clarity. We optimized injection parameters (280–310°C barrel temp, 120°C mold temp) to avoid cloudiness and added a dual-layer coating: UV-stabilizer (previene el amarillamiento) + hard-coat (2H scratch resistance). Post-molding, we annealed lenses at 120°C for 1.5 horas para reducir el estrés interno.

• Resultados: The PC lenses passed all safety tests (shatterproof when struck with a 2kg steel ball) and retained 88% clarity after 5 years of accelerated weather testing (VS. acrylic’s 60%). The automaker expanded their order to 500,000 units/year and switched all their vehicle lines to our PC headlights.​

Estudio de caso 2: BPA-Free PC Medical Inhaler Housings​

• Desafío: A pharmaceutical company needed 100,000 inhaler housings that were BPA-free (meets FDA/EFSA standards), ligero (≤20g), y resistente al impacto (to survive drops from 1.2m). Their previous PP housings were too flexible and warped after sterilization.​

• Solución: Seleccionamos BPA-free PC (resistencia a la tracción 65 MPA) and designed thin-walled molds (1.5espesor de la pared mm) Para reducir el peso. We used nitrogen gas assist during injection to ensure uniform filling of the housing’s intricate vents (critical for airflow). Post-molding, we added a soft-touch texturing (via chemical etching) to improve grip for patients with limited dexterity.​

• Resultados: The BPA-free PC housings weighed 18g (meeting the client’s target), aprobado 100+ óxido de etileno (Póngase en fila) sterilization cycles with no warping, y sobrevivido 50 pruebas de caída (1.2metro) sin grietas. El cliente informó un 30% increase in patient satisfaction due to the improved grip, Y ahora producimos 200,000 housings/month for their global inhaler line.​

Estudio de caso 3: Hard-Coated PC Smartphone Screen Protectors​

• Desafío: Se necesitaba una marca de electrónica de consumo 1 million smartphone screen protectors that were clear (≥88% transmittance), resistente a los arañazos (3H pencil hardness), and compatible with touchscreens (no impact on sensitivity). Their previous uncoated PC protectors scratched easily and reduced screen clarity.​

• Solución: Usamos general-purpose PC (90% transmitancia) and developed a proprietary hard-coating process: spraying a silicone-based coating (5μm thickness) and curing it at 100°C for 30 minutos. We optimized mold design to produce ultra-thin protectors (0.3milímetros) that didn’t affect touch sensitivity and added a anti-fingerprint layer (via UV-cured ink) to reduce smudges.​

Resultados: The hard-coated PC protectors met 3H scratch resistance (survived scratches from keys and coins), retenido 89% claridad, and had no impact on touch sensitivity (tested with 10,000 grietas). They sold out within 2 Meses de lanzamiento, and the brand expanded their order to 2 million units/quarter—citing our “perfect balance of clarity and durability.”

Why Choose Us for Your PC Injection Molding Needs?

With countless injection molding suppliers offering PC services, Yigu Technology stands out for our deep specialization in PC, uncompromising quality, and client-centric approach. Here’s why leading brands in automotive, médico, and electronics trust us:​

1. Specialized PC Expertise​

We don’t just mold plastics—we specialize in Polycarbonate. Nuestros ingenieros tienen 20+ years of experience solving PC’s unique challenges:​

• Moisture sensitivity: Proprietary drying protocols (a <0.02% humedad) that eliminate bubbles and yellowing.​

• Claridad óptica: Mold polishing to Ra 0.02 μm (acabado espejo) for lenses and headlights.​

• Resistencia al calor: Process optimization for glass-filled PC (PC-GF30) to retain strength at 140°C.​

We’ve worked with every PC grade (uso general, Sin BPA, óptico, reciclado) and know how to tailor processes to your exact application—something generalist molders can’t match.​

2. Garantía de calidad rigurosa

Quality is non-negotiable for PC parts (especially optical and medical). Sostenemos ISO 9001 (fabricación general) y ISO 13485 (fabricación de dispositivos médicos) certificaciones, con un 99.7% defect-free rate for PC components. Nuestros controles de calidad incluyen:​

• Pre-moldeo: Moisture testing (Karl Fischer titration) to ensure PC pellets are dry (<0.02%).​

• En moldeo: Real-time laser measurement (±0.001mm tolerance) and vision inspection for surface defects (arañazos, cloudiness).​

• Post-molding:​

• Clarity testing (haze meter for optical parts: ≤0.5% haze).​

• Prueba de impacto (Notched Izod: ≥60 kJ/m² for general-purpose PC).​

• Regulatory compliance (FDA 21 CFR 177.1580 for BPA-free PC; UL94 V0 for flame-retardant PC).​

3. Servicio centrado en el cliente

Tratamos su proyecto como si fuera nuestro. Desde el primer día, Trabajará con un administrador de cuentas dedicado que:​

• Provides free material/design consultations (P.EJ., helping you choose between optical-grade PC and hard-coated PC for lenses).​

• Shares 3D mold designs and sample parts (dentro 5 días) for approval before full production.​

• Ofrece horarios de entrega flexibles: 4–6 días para prototipos (moldes de aluminio), 3–5 semanas para carreras de alto volumen (moldes de acero).​

• Brindar 24/7 support for urgent issues (P.EJ., expediting orders for product launches).​

4. Soluciones innovadoras

Invertimos 10% de nuestros ingresos anuales en R&D to push the boundaries of PC injection molding. Las innovaciones recientes incluyen:​

• Ultra-Clear rPC: A recycled PC grade (rPC) con 85% transmitancia de luz (VS. standard rPC’s 70–80%)—ideal for semi-optical parts like smartphone casings.​

• Fast-Cure Hard-Coat: A coating that cures in 15 minutos (VS. 30 minutos) without reducing scratch resistance—cuts production time for screen protectors by 20%.​

• Low-Temp Molding for BPA-Free PC: A process that reduces barrel temperature by 10°C (to 250–290°C) for BPA-free PC—prevents thermal degradation and improves part consistency.​

5. Prácticas sostenibles

We’re committed to reducing our environmental impact while delivering top-tier PC parts:​

• Recycled PC (rPC): Fuiamos 45% of our PC materials from post-industrial waste (P.EJ., PC scrap from electronics manufacturing) and offer rPC grades that cost 15–25% less than virgin PC.​

• Reducción de desechos: Recicamos 97% de chatarra de producción (destello, partes defectuosas) back into the molding process—sending only 3% a vertederos.

Eficiencia energética: Our injection molding machines use heat recovery systems to reuse 30% of the heat from barrel heating—reducing energy consumption by 25% VS. standard machines.

Preguntas frecuentes