Home appliance shell injection mold

Robot Dog Sonar Lens Injection Mold: Core Parts Analysis (Including Manufacturing Process & Industry Standards)

The sonar lens is the core component of a robot dog’s perception system—its performance directly hinges on the precision and reliability of the injection mold. Having worked in the injection mold industry for years, we’ve accumulated rich experience in producing sonar lens molds for intelligent equipment. Below, we’ll break down the key technical points of these molds from the perspectives of structure, core part materials, manufacturing processes, and industry applications. We’ll also share our actual production cases to provide practical references for industry clients.

1. Core Part Composition & Functional Design: The Foundation of Precision

The robot dog sonar lens housing has strict requirements: high-precision dimensions (tolerance ±0.01mm), optical-grade surface finish (Ra≤0.025μm), and resistance to environmental stress cracking. From our production practice, the three core parts of the injection mold directly determine the product quality:

• Cavity Insert Assembly: We usually choose NAK80 pre-hardened steel or S136 stainless steel. Combining CNC precision carving with EDM electrical discharge machining ensures the stability of cavity dimensions. The mirror polishing level reaches SPI#12000—this is crucial to avoid weld lines or gas marks on the lens surface, which would affect the sonar signal transmission.

• Hot Runner System: Needle valve hot nozzles from well-known brands like Mold-Master or Yudo are our go-to choice. The temperature control error is within ±1℃, which effectively solves the problem of unbalanced filling in multi-cavity molds. For example, in a 4-cavity mold, the difference between each cavity can be controlled within 2%.

• Positioning & Guiding Mechanism: We use DME standard precision guide pillars and bushes, paired with conical positioning blocks (HRC58-62). This ensures the mold clamping precision is within 0.005mm, preventing assembly deviation of the sonar lens—an issue that could lead to inaccurate perception.

2. Material Selection & Manufacturing Process Control: Balancing Performance & Durability

The sonar lens is usually made of PC/ABS, which has high fluidity requirements. Therefore, the mold steel must balance wear resistance and corrosion resistance. Here’s our practical material and process configuration:

• Cavity Insert: S136H steel undergoes vacuum heat treatment (1050℃ quenching + 520℃ tempering), achieving a hardness of HRC48-52. It can pass a salt spray test of ≥500 hours without rusting, suitable for long-term mass production.

• Inserts: The sprue bush is made of tungsten steel (YG8), which improves wear resistance by 30%. This is particularly suitable for injection scenarios with high glass fiber-filled materials.

• Surface Treatment: The mold cavity is coated with hard chrome + PTFE. We set the draft angle at ≥1°, which increases the product ejection yield to 99.8%—a key improvement for reducing production waste.

3. Production Cycle & Quality Control: Delivering Efficiency Without Compromising Quality

Through concurrent engineering, we’ve achieved fast delivery in 25 days while ensuring quality. Here’s how we do it in practice:

• Design Phase: We use Moldflow analysis to optimize the gating system, which reduces the holding pressure time by 30% and shortens the overall injection cycle.

• Processing Stage: 5-axis CNC machining is used for complex curved surfaces with a step distance of ≤0.1mm. We conduct full-dimensional verification with a CMM (Coordinate Measuring Machine) to ensure every detail meets the design requirements.

• Trial Mold Verification: We have 100T-500T injection molding machines available. We also offer free sampling services, including a detailed material property test report, so clients can verify product performance before mass production.

4. Industry Applications & Customization Services: Tailored Solutions for Diverse Needs

Over the years, we’ve provided mold solutions for more than 20 industries. Our typical cases include:

• Digital Products: Drone lens molds with an annual production capacity of 500,000 units.

• Medical Equipment: Endoscope housing molds that meet ISO13485 certification standards.

• Home Appliance Connectors: High-temperature resistant PA66 plug molds that can run 3 million cycles continuously without mold repair.

We support customization based on client drawings or samples, offering a full-chain service from mold design and tooling to injection production. We guarantee that all products fully comply with international standards (DIN/ISO/JIS), giving clients peace of mind about quality and compliance.