Our Polycarbonate PC Injection Molding Services

Elevate your high-performance production with Yigu Technology’s premium Polycarbonate (PC) Services de moulage par injection—where clarity meets durability. Leveraging our injection molding expertise, advanced machinery, and custom tooling, we deliver precision-molded PC parts that excel in impact resistance, tolérance à la chaleur, and transparency—perfect for automotive, électronique grand public, dispositifs médicaux, and optical applications demanding uncompromising quality.​

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Qu'est-ce que le polycarbonate (PC) Moulage par injection?

Polycarbonate (PC) is a high-performance thermoplastic polymer renowned for its exceptional balance of strength, clarté, et résistance à la chaleur. 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. Moulage par injection is a manufacturing process that melts PC pellets, injects the molten material into a custom mold cavity, cools it to solidify, and ejects the finished part. Ensemble, Moulage par injection PC produces robust, transparent (or opaque) components that thrive in demanding environments—from shatterproof eyeglass lenses to heat-resistant automotive headlights.​

Définitions clés & Core Concepts​

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Material Properties of PC​

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

• Résistance à l'impact élevé: Notched Izod impact strength of 60–80 kJ/m²—20x stronger than glass, 10x stronger than acrylic, and shatterproof (even when struck hard).​

• Clarity & Transparence: 90% transmittance légère (contre. acrylic’s 92%—negligible difference) with low haze (≤1%), making it ideal for optical applications.​

• Résistance à la chaleur: Continuous use temperature (CUT) of 120–140°C; can withstand short-term exposure to 180°C (Par exemple, automotive engine bay heat or medical sterilization).​

• Stabilité dimensionnelle: Faible coefficient d'expansion thermique (Cte: 6.7–7.0 × 10⁻⁵/°C)—retains shape even when exposed to temperature fluctuations (critical for precision parts like optical lenses).​

Résistance chimique: Résistant aux huiles, graisses, Et la plupart des produits chimiques ménagères (except strong acids/bases like sulfuric acid or ammonia).

Nos capacités: Delivering High-Performance PC Injection Molding

À la technologie Yigu, we specialize in PC injection molding—our capabilities are tailored to handle PC’s unique processing challenges (point de fusion élevé, sensibilité à l'humidité, viscosity) and deliver parts that meet the strictest industry standards (Par exemple, FDA pour les dispositifs médicaux, OIN 10366 for optical components).​

Répartition des capacités de base

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The PC Injection Molding Process: Step-by-Step Precision

PC’s unique characteristics—high melting point, sensibilité à l'humidité, and high viscosity—require a specialized, optimized process to maintain clarity, force, et stabilité dimensionnelle. Our workflow minimizes defects and maximizes performance, whether you’re producing 50 optical lens prototypes or 500,000 smartphone casings.​

Étape 1: Préparation des matériaux (Critical for PC)​

PC absorbs moisture rapidly (jusqu'à 0.3% of its weight in 24 des heures de 50% humidité), qui provoque hydrolytic degradation (jaunissant, bulles, or reduced impact strength) during molding. Our preparation process eliminates this risk:​

• Séchage: 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) to reduce moisture content to <0.02%.​

• Additive/Filler Blending: Mix dried pellets with additifs (UV stabilizers for outdoor use, flame retardants for electronics) ou remplissage (glass fiber for extra strength, carbon fiber for conductivity—note: fillers reduce clarity).​

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

Étape 2: Conception de moisissure (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 (Par exemple, thin-walled electronics casings).​

• Systèmes de refroidissement: Uniform water-cooling channels (spaced 20–30mm apart) to prevent uneven cooling (which causes warping or cloudiness); mold temperature maintained at 80–120°C (higher than most plastics) to reduce internal stress.​

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

Étape 3: Injection Parameters (Tailored to PC Grades)​

PC’s high melting point and viscosity require precise parameter tuning to avoid degradation (jaunissant) or incomplete filling. Below are standard settings for two common grades:​

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Étape 4: Opérations post-moulage

Après démouloir, PC parts may undergo:​

• Garniture: Removing flash (excès de plastique) with diamond-coated tools (to avoid scratching PC’s surface—critical for optical parts).​

• Recuit: Heating parts to 110–130°C for 1–2 hours, puis refroidir lentement (5–10°C/hour) Pour réduire le stress interne (prevents cracking in high-temperature applications like automotive headlights).​

• Traitement de surface: Applying coatings, texturation, or printing (Voir section 5 pour plus de détails).​

• Inspection: QC checks for:​

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

• Précision dimensionnelle: Laser measurement (±0.001mm for optical parts).​

Résistance à l'impact: Notched Izod testing (≥60 kJ/m² for general-purpose PC).

Matériels: Choosing the Right PC Grade for Your Project

Not all PC is the same—each grade is tailored to specific applications, balancing clarity, force, et coûter. Selecting the right grade ensures your parts meet performance, réglementaire, and design goals.​

Common PC Types for Injection Molding​

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Conseils de sélection des matériaux

1. Prioritize clarity vs. force: For optical applications (lentilles), choose optical-grade PC; pour les parties structurelles (supports automobiles), pick glass-filled PC (trade clarity for strength).​

2. Check regulatory needs: For food/medical contact, use BPA-free PC (rencontre la FDA 21 CFR 177.1580); pour l'électronique, use flame-retardant PC (meets UL94 V0).​

Adopter la durabilité: Our rPC is ideal for brands focused on eco-friendly practices—use it for opaque, pièces non critiques (Par exemple, colored smartphone cases) to cut costs and reduce environmental impact.

Traitement de surface: Enhancing PC’s Function & Esthétique

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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Avantages: Why Choose PC Injection Molding?

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

Key Advantages of PC Injection Molding​

• Résistance à l'impact élevé: 20x stronger than glass and 10x stronger than acrylic—PC parts are shatterproof (Par exemple, a PC water bottle won’t break if dropped, unlike glass or acrylic).​

• Clarity & Transparence: 90% transmittance légère (nearly as clear as glass) with the flexibility of plastic—ideal for optical applications (lentilles) et produits de consommation (enveloppes transparentes).​

• Résistance à la chaleur: 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).​

• Stabilité dimensionnelle: Faible extension thermique (6.7 × 10⁻⁵/°C) contre. acrylique (17 × 10⁻⁵/°C)—PC parts retain shape in temperature fluctuations (critical for precision parts like optical lenses).​

• Personnalisation: Accepts additives (UV/flame retardants), remplissage (fibre de verre), et traitements de surface (hard-coat, impression)—adapts to any application, from opaque structural parts to ultra-clear optics.​

PC VS. Other Transparent Injection Molding Plastics​

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Industrie des applications: Where PC Injection Molding Excels

PC versatility—blending strength, clarté, and heat resistance—makes it indispensable in five key industries. Below are real-world use cases and our tailored solutions:​

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Études de cas: 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, force, et les performances. Below are three standout projects:​

Étude de cas 1: Optical-Grade PC Automotive Headlight Lenses​

• Défi: Un principal constructeur automobile nécessaire 300,000 headlight lenses that were ultra-clear (≥90% light transmittance), incassable (Pour répondre aux normes de sécurité), and resistant to yellowing (pour 5+ années d'utilisation en plein air). Their previous acrylic lenses cracked easily and yellowed after 2 années.

• Solution: Nous avons utilisé optical-grade PC (92% transmission) and designed custom hardened steel molds with mirror-polished cavities (Rampe 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 (Empêche le jaunissement) + hard-coat (2H scratch resistance). Post-molding, we annealed lenses at 120°C for 1.5 hours to reduce internal stress.​

• Résultats: 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 (contre. acrylic’s 60%). The automaker expanded their order to 500,000 units/year and switched all their vehicle lines to our PC headlights.​

Étude de cas 2: BPA-Free PC Medical Inhaler Housings​

• Défi: A pharmaceutical company needed 100,000 inhaler housings that were BPA-free (meets FDA/EFSA standards), léger (≤20g), et résistant à l'impact (to survive drops from 1.2m). Their previous PP housings were too flexible and warped after sterilization.​

• Solution: Nous avons sélectionné BPA-free PC (résistance à la traction 65 MPA) and designed thin-walled molds (1.5épaisseur de paroi mm) Pour réduire le poids. 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.​

• Résultats: The BPA-free PC housings weighed 18g (meeting the client’s target), passé 100+ oxyde d'éthylène (S'aligner) sterilization cycles with no warping, et a survécu 50 tests de dépôt (1.2m) sans fissures. Le client a signalé un 30% increase in patient satisfaction due to the improved grip, Et nous produisons maintenant 200,000 housings/month for their global inhaler line.​

Étude de cas 3: Hard-Coated PC Smartphone Screen Protectors​

• Défi: Une marque d'électronique grand public avait besoin 1 million smartphone screen protectors that were clear (≥88% transmittance), résistant aux rayures (3H pencil hardness), and compatible with touchscreens (no impact on sensitivity). Their previous uncoated PC protectors scratched easily and reduced screen clarity.​

• Solution: Nous avons utilisé general-purpose PC (90% transmission) and developed a proprietary hard-coating process: spraying a silicone-based coating (5µm d'épaisseur) and curing it at 100°C for 30 minutes. We optimized mold design to produce ultra-thin protectors (0.3MM) that didn’t affect touch sensitivity and added a anti-fingerprint layer (via UV-cured ink) to reduce smudges.​

Résultats: The hard-coated PC protectors met 3H scratch resistance (survived scratches from keys and coins), retenu 89% clarté, and had no impact on touch sensitivity (tested with 10,000 tapissements). They sold out within 2 mois de lancement, 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, médical, and electronics trust us:​

1. Specialized PC Expertise​

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

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

• Clarté optique: Mold polishing to Ra 0.02 µm (finition miroir) for lenses and headlights.​

• Résistance à la chaleur: Process optimization for glass-filled PC (PC-GF30) to retain strength at 140°C.​

We’ve worked with every PC grade (à usage général, Sans BPA, optique, recyclé) and know how to tailor processes to your exact application—something generalist molders can’t match.​

2. Rigorous Quality Assurance​

Quality is non-negotiable for PC parts (especially optical and medical). Nous tenons OIN 9001 (fabrication générale) et OIN 13485 (fabrication de dispositifs médicaux) certifications, avec un 99.7% defect-free rate for PC components. Our quality checks include:​

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

• In-molding: Real-time laser measurement (±0.001mm tolerance) and vision inspection for surface defects (rayures, cloudiness).​

• Post-molding:​

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

• Tests d'impact (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. Customer-Focused Service​

We treat your project as if it’s our own. From day one, you’ll work with a dedicated account manager who:​

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

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

• Offers flexible lead times: 4–6 days for prototypes (moules en aluminium), 3–5 weeks for high-volume runs (moules en acier).​

• Proposer 24/7 support for urgent issues (Par exemple, expediting orders for product launches).​

4. Solutions innovantes

Nous investissons 10% de nos revenus annuels en r&D to push the boundaries of PC injection molding. Recent innovations include:​

• Ultra-Clear rPC: A recycled PC grade (rPC) avec 85% transmittance légère (contre. standard rPC’s 70–80%)—ideal for semi-optical parts like smartphone casings.​

• Fast-Cure Hard-Coat: A coating that cures in 15 minutes (contre. 30 minutes) 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. Sustainable Practices​

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

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

• Réduction des déchets: Nous recyclons 97% of production scrap (éclair, parties défectueuses) back into the molding process—sending only 3% to landfills.​

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

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