1. Basic requirements for injection molding materials used in consumer electronics
The main distinction between and industrial parts is that consumer electronics need to be very precise, very integrated, and look good. When picking materials for injection molding, you normally have to think about the following things:
How it looks and works
The outside and visible elements of consumer electronics need to have a smooth and shiny finish. This can be done via spraying, silk screening, laser engraving, or electroplating. The way plastic materials look and how well they mold directly determine how the finished product looks.
Stability and precision of dimensions
gadgets need to be put together with great care. Plastic parts need to be able to be used for a long time without bending or warping. This is especially important for thin-walled structures, buckles, and interface points that need to be very precise.
2. ABS: The most popular material used for injection molding in the consumer electronics industry
**Acrylonitrile butadiene styrene copolymer (ABS) is one of the most prevalent polymers utilized in the electronics sector. It strikes a good mix between formability, surface quality, and mechanical qualities, and its costs are reasonably easy to regulate. This is why it is the most popular choice for shells and decorative elements.
Main Features:
Good formability: It has a medium level of fluidity, is easy to inject mold, and can mold thin-walled parts without breaking.
High surface quality: it's easy to get high gloss, matte, or textured effects. It's good for spray painting, screen printing, and laser engraving.
Strong impact resistance: can be used every day and throughout shipping without breaking.
3. PC and PC+ABS are strong and heat-resistant materials.
PC (polycarbonate) and its PC+ABS materials blended with ABS are the most popular choice when items need to be stronger, more heat-resistant, or safer.
Features of PC (polycarbonate):
Strong against impact and great at withstanding drops
It can handle high temperatures well and is stable in size.
Good see-through quality; can be used for lampshades or clear shells
What PC+ABS has:
Finding a balance between how strong PC is and how easy it is to work with ABS
Low shrinkage rate when molding, which makes it better for thin-walled or complicated constructions
It's easy to spray on the surface, and it looks beautiful.
It meets safety criteria and works well in high temperatures and with flames.
Common uses:
Shell for a laptop
Back cover of the monitor
Structural parts for high-end smart devices
Housing for the power adapter
PC+ABS is a material that is virtually always needed in consumer electronics that are mid to high end. It works well for thin-walled, complicated structures and parts that need to be able to take a lot of impact.
4. Engineering plastics like POM (Saigang) and PA (nylon)
Functional parts inside consumer electronics need to be stronger, more resistant to wear, and more stable in size than parts on the outside. PA and POM are two types of engineering plastics that are often utilized.
Nylon (PA)
Strong and resistant to wear
Very good at stretching and not getting tired
Good for structural parts like brackets and buckles
POM (polyoxymethylene)
Very precise dimensions and resistance to friction
Good ability to lubricate itself
Good for gears, sliding parts, and button structures
Common uses:
Brackets are structural parts that hold up loads inside
Gears and systems that rotate with precision
Buttons and buckles for electronic products
Parts that are used a lot at high frequencies, such the mouse scroll wheel
In consumer electronics, PA and POM are mostly used as structural parts. Their looks are mediocre, but their performance and dependability are what make them invaluable.
5. TPU, TPE, and other types of flexible polymers
As more and more people want consumer gadgets that are light, easy to use, and safe, elastic plastic materials are employed a lot in both appearance and functional parts.
TPU (thermoplastic polyurethane) and TPE (thermoplastic elastomer) have these features:
Soft to the touch and able to bounce back well
Shock- and slip-resistant, which makes the product easier to hold.
With hard materials, you can do dual color injection molding or encapsulation molding.
Common uses:
Case for a mobile phone, strap for a watch
Buttons and rubber casing
Protective padding and cushioning parts
Waterproof ring, sealing ring
Using dual color molds or encapsulation methods, elastic materials can be combined with PC/ABS shells to find a compromise between how they look and how well they work.
