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Metal insert connector injection mold customization is a specialized solution for manufacturing high-performance electrical connectors—critical components in automotive electronics, consumer devices, and industrial control systems. Unlike standard injection molds, it focuses on seamless integration of metal inserts (e.g., brass pins, stainless steel sleeves) with plastic housings, ensuring tight bonding, stable electrical conductivity, and resistance to vibration or temperature shifts. This customization addresses the unique challenge of preventing insert displacement during 注塑，a key factor in avoiding connector failure.
1. Tailored for Connector Diversity
We customize molds to match specific connector types—from USB-C ports and automotive PCB connectors to industrial sensor connectors. This includes optimizing cavity layouts (1-out-2 for low-volume, 1-out-6 for mass production), designing precision insert-locating structures (with ±0.005mm tolerance for locating pins), and adapting to insert sizes (0.3mm–8mm diameter) and materials (brass, phosphor bronze, or stainless steel for corrosion resistance).
2. High-Precision Insert Fixing
Molds feature anti-rotation slots and pre-locking mechanisms to secure inserts during injection, ensuring insert-plastic coaxiality ≤0.01mm. This eliminates risks of loose inserts or misaligned contact points, which cause electrical contact failure. We also optimize plastic flow paths (via MoldFlow simulation) to avoid pressure concentrations that could damage delicate inserts.
3. Durability for Mass Production
Mold cores and cavities use high-grade S136 or H13 steel, heat-treated to HRC 52–54 and coated with hard chrome (5–8μm thick). This enables 300,000+ stable injection cycles—ideal for high-volume connector manufacturing (e.g., 500k+ units/month for automotive suppliers).
Our process starts with analyzing your connector’s 3D model (checking insert placement and plastic wall thickness) and defining requirements (e.g., pull-out force ≥50N for inserts, IP65 waterproofing for housings). Next, we run mold flow simulations to optimize cooling circuits (preventing plastic shrinkage around inserts) and conduct 2–3 trial molds to validate dimensional accuracy (via coordinate measuring machines) and insert bonding strength.
• Automotive: In-vehicle USB chargers, sensor connectors (withstanding -40℃ to 125℃).
• Consumer Electronics: Smartphone charging ports, laptop dock connectors.
• Industrial Control: PLC communication connectors, industrial Ethernet ports (resisting dust and moisture).
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