Our Polycarbonate PC Injection Molding Services

Elevate your high-performance production with Yigu Technology’s premium Поликарбонат (ПК) Injection Molding services—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, теплоемкость, and transparency—perfect for automotive, потребительская электроника, медицинские устройства, and optical applications demanding uncompromising quality.​

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Что такое поликарбонат (ПК) Инъекционное формование?

Поликарбонат (ПК) is a high-performance thermoplastic polymer renowned for its exceptional balance of strength, ясность, и теплостойкость. 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. Инъекционное формование 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. Вместе, Инъекция ПК produces robust, прозрачный (or opaque) components that thrive in demanding environments—from shatterproof eyeglass lenses to heat-resistant automotive headlights.​

Key Definitions & 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:​

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

• Clarity & Прозрачность: 90% легкая коэффициент пропускания (против. acrylic’s 92%—negligible difference) with low haze (≤1%), making it ideal for optical applications.​

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

• Размерная стабильность: Низкий коэффициент термического расширения (CTE: 6.7–7.0 × 10⁻⁵/°C)—retains shape even when exposed to temperature fluctuations (critical for precision parts like optical lenses).​

Химическая устойчивость: Устойчив к маслам, смазки, и большинство бытовых химикатов (except strong acids/bases like sulfuric acid or ammonia).

Наши возможности: Delivering High-Performance PC Injection Molding

В Yigu Technology, we specialize in PC injection molding—our capabilities are tailored to handle PC’s unique processing challenges (высокая точка плавления, Чувствительность влаги, viscosity) and deliver parts that meet the strictest industry standards (НАПРИМЕР., FDA для медицинских устройств, Iso 10366 for optical components).​

Основные возможности поломки

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

PC’s unique characteristics—high melting point, Чувствительность влаги, and high viscosity—require a specialized, optimized process to maintain clarity, сила, и размерная стабильность. Our workflow minimizes defects and maximizes performance, whether you’re producing 50 optical lens prototypes or 500,000 smartphone casings.​

Шаг 1: Материал подготовка (Critical for PC)​

PC absorbs moisture rapidly (до 0.3% of its weight in 24 часы в 50% влажность), что вызывает hydrolytic degradation (пожелтение, пузырьки, or reduced impact strength) during molding. Our preparation process eliminates this risk:​

• Сушка: 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 добавки (UV stabilizers for outdoor use, flame retardants for electronics) или наполнители (glass fiber for extra strength, carbon fiber for conductivity—note: fillers reduce clarity).​

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

Шаг 2: Дизайн плесени (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 (НАПРИМЕР., thin-walled electronics casings).​

• Cooling Systems: 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 (линзы, prisms) have mirror-polished surfaces (Раствор <0.02 мкм) and no parting lines (to avoid light scattering); use of hot runner systems to prevent material degradation in cold runners.​

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

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

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Шаг 4: Post-Molding Operations​

After demolding, PC parts may undergo:​

• Обрезка: Removing flash (Избыток пластика) with diamond-coated tools (to avoid scratching PC’s surface—critical for optical parts).​

• Отжиг: Heating parts to 110–130°C for 1–2 hours, Затем медленно охлаждение (5–10°C/hour) Чтобы уменьшить внутренний стресс (prevents cracking in high-temperature applications like automotive headlights).​

• Поверхностная обработка: Applying coatings, текстурирование, or printing (См. Раздел 5 Для получения подробной информации).​

• Осмотр: QC checks for:​

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

• Точность размеров: Laser measurement (±0.001mm for optical parts).​

Воздействие сопротивления: Notched Izod testing (≥60 kJ/m² for general-purpose PC).

Материалы: Choosing the Right PC Grade for Your Project

Not all PC is the same—each grade is tailored to specific applications, balancing clarity, сила, и стоимость. Selecting the right grade ensures your parts meet performance, регулирующий, and design goals.​

Common PC Types for Injection Molding​

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Material Selection Tips​

1. Prioritize clarity vs. сила: For optical applications (линзы), choose optical-grade PC; Для структурных частей (Автомобильные кронштейны), pick glass-filled PC (trade clarity for strength).​

2. Check regulatory needs: For food/medical contact, use BPA-free PC (встречает FDA 21 CFR 177.1580); для электроники, use flame-retardant PC (meets UL94 V0).​

Embrace sustainability: Our rPC is ideal for brands focused on eco-friendly practices—use it for opaque, некритические части (НАПРИМЕР., colored smartphone cases) to cut costs and reduce environmental impact.

Поверхностная обработка: Enhancing PC’s Function & Эстетика

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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Преимущества: Why Choose PC Injection Molding?

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

Key Advantages of PC Injection Molding​

• Высокая ударная стойкость: 20x stronger than glass and 10x stronger than acrylic—PC parts are shatterproof (НАПРИМЕР., a PC water bottle won’t break if dropped, unlike glass or acrylic).​

• Clarity & Прозрачность: 90% легкая коэффициент пропускания (nearly as clear as glass) with the flexibility of plastic—ideal for optical applications (линзы) и потребительские товары (прозрачные оболочки).​

• Теплостойкость: 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).​

• Размерная стабильность: Низкое тепловое расширение (6.7 × 10⁻⁵/°C) против. акрил (17 × 10⁻⁵/°C)—PC parts retain shape in temperature fluctuations (critical for precision parts like optical lenses).​

• Настраиваемость: Accepts additives (UV/flame retardants), наполнители (стеклянное волокно), и поверхностная обработка (hard-coat, печать)—adapts to any application, from opaque structural parts to ultra-clear optics.​

ПК против. Other Transparent Injection Molding Plastics​

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Индустрия приложений: Where PC Injection Molding Excels

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

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Тематические исследования: 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, сила, и производительность. Below are three standout projects:​

Тематическое исследование 1: Optical-Grade PC Automotive Headlight Lenses​

• Испытание: Нужен ведущий автомобильный производитель 300,000 headlight lenses that were ultra-clear (≥90% light transmittance), Разбитый (Чтобы соответствовать стандартам безопасности), and resistant to yellowing (для 5+ Годы использования на открытом воздухе). Their previous acrylic lenses cracked easily and yellowed after 2 годы

• Решение: Мы использовали optical-grade PC (92% коэффициент пропускания) and designed custom hardened steel molds with mirror-polished cavities (Раствор 0.02 мкм) 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 (Предотвращает пожелтеть) + hard-coat (2H scratch resistance). Post-molding, we annealed lenses at 120°C for 1.5 hours to reduce internal stress.​

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

Тематическое исследование 2: BPA-Free PC Medical Inhaler Housings​

• Испытание: A pharmaceutical company needed 100,000 inhaler housings that were BPA-free (meets FDA/EFSA standards), легкий вес (≤20g), и воздействие (to survive drops from 1.2m). Their previous PP housings were too flexible and warped after sterilization.​

• Решение: Мы выбрали BPA-free PC (предел прочности 65 МПА) and designed thin-walled molds (1.5ММ толщина стены) Чтобы уменьшить вес. 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.​

• Результаты: The BPA-free PC housings weighed 18g (meeting the client’s target), прошедший 100+ этиленоксид (Расстановка) sterilization cycles with no warping, и выжил 50 сбрасывание тестов (1.2м) без трещин. Клиент сообщил 30% increase in patient satisfaction due to the improved grip, И теперь мы производим 200,000 housings/month for their global inhaler line.​

Тематическое исследование 3: Hard-Coated PC Smartphone Screen Protectors​

• Испытание: Необходим бренд потребительской электроники 1 million smartphone screen protectors that were clear (≥88% transmittance), царапина (3H pencil hardness), and compatible with touchscreens (no impact on sensitivity). Their previous uncoated PC protectors scratched easily and reduced screen clarity.​

• Решение: Мы использовали general-purpose PC (90% коэффициент пропускания) and developed a proprietary hard-coating process: spraying a silicone-based coating (5толщина мкм) and curing it at 100°C for 30 минуты. We optimized mold design to produce ultra-thin protectors (0.3мм) that didn’t affect touch sensitivity and added a anti-fingerprint layer (via UV-cured ink) to reduce smudges.​

Результаты: The hard-coated PC protectors met 3H scratch resistance (survived scratches from keys and coins), сохраняется 89% ясность, and had no impact on touch sensitivity (tested with 10,000 нажатие). They sold out within 2 месяцы запуска, 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, медицинский, and electronics trust us:​

1. Specialized PC Expertise​

We don’t just mold plastics—we specialize in Polycarbonate. У наших инженеров есть 20+ years of experience solving PC’s unique challenges:​

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

• Оптическая ясность: Mold polishing to Ra 0.02 мкм (Зеркальное отделка) for lenses and headlights.​

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

We’ve worked with every PC grade (Общий назначение, Без BPA, оптический, переработан) 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). Мы держим Iso 9001 (Общее производство) и Iso 13485 (Производство медицинских устройств) сертификаты, с 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 (царапины, cloudiness).​

• Post-molding:​

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

• Ударный тестирование (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 (НАПРИМЕР., helping you choose between optical-grade PC and hard-coated PC for lenses).​

• Shares 3D mold designs and sample parts (в пределах 5 дни) for approval before full production.​

• Offers flexible lead times: 4–6 days for prototypes (алюминиевые формы), 3–5 weeks for high-volume runs (стальные формы).​

• Обеспечивает 24/7 support for urgent issues (НАПРИМЕР., expediting orders for product launches).​

4. Инновационные решения

Мы инвестируем 10% нашего годового дохода в R&D to push the boundaries of PC injection molding. Recent innovations include:​

• Ultra-Clear rPC: A recycled PC grade (rPC) с 85% легкая коэффициент пропускания (против. standard rPC’s 70–80%)—ideal for semi-optical parts like smartphone casings.​

• Fast-Cure Hard-Coat: A coating that cures in 15 минуты (против. 30 минуты) 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): Мы источны 45% of our PC materials from post-industrial waste (НАПРИМЕР., PC scrap from electronics manufacturing) and offer rPC grades that cost 15–25% less than virgin PC.​

• Сокращение отходов: We recycle 97% of production scrap (вспышка, дефектные части) back into the molding process—sending only 3% to landfills.​

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

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