I. Detailed Time Consumption for Each Stage
Preliminary Simulation and Scheme Design Stage: 2-3 days. Conduct a comprehensive Moldflow simulation, generate optimised schemes for runner layout, temperature control zoning, and gate size, and predict the likelihood of uneven filling.
Mould Hardware Modification and Processing Stage: 7-10 days. Complete hardware modifications, including the upgrading of the hot runner temperature control module, the modification of the conformal water channel, and the unification of the gate and venting systems.
Stage of Deployment for Sensors and Digital Systems: 1-2 days. Complete the installation of pressure sensors in each cavity mould, the deployment of IoT data acquisition gateways, and the calibration and refining of the temperature control system.
Debugging and Verification of Processes on-Site Stage: 2-3 days. Perform numerous parameter trial adjustments, calibrate the filling time difference of each cavity, and confirm that the filling consistency index satisfies the established standards.
Verification of Mass Production Stability Stage: Three to five days. To ensure that the filling consistency remains consistent over the course of a long-term production cycle and to solidify the mature process parameters, continuous mass production of over 100,000 units is necessary.
II. Explanation of the Total Cycle Timeframe The typical cumulative cycle time is 15-23 days. If the mould is in excellent condition and no significant hardware modifications are necessary, the total cycle time can be reduced to 5-7 days by optimising the process and parameters.
The total cycle time will be extended to approximately 30 days for complex precision moulds with a high number of cavities (32 or more per cavity) to ensure that the filling consistency of each cavity completely meets the standards.
This timeframe is appropriate for the optimisation scenarios of the majority of precision hot runner multi-cavity moulds and can be easily modified to accommodate the actual operating conditions of the production line.
