Perfectly Bonding ABS with PU in Machine Parts Manufacturing
Client introduction
INDSATSEN ApS from Denmark has established itself as a prominent leader in the machinery and equipment wholesale sector. We were fortunate to collaborate with them to tackle a range of highly challenging production issues.
The challenge
Firstly, the client needed an ideal blend of ABS (Acrylonitrile Butadiene Styrene) and PU (Polyurethane) to ensure a strong bond, prevent degumming, and guarantee the product’s durability and stability.
Secondly, the ABS component must remain undeformed after encapsulation to allow smooth installation of the test core, demanding high precision in the production process.
Thirdly, the product’s surface must be free of bubbles, as they not only mar the appearance but also threaten product quality.
Lastly, the product’s hardness and color must be uniform.
To meet our client’s stringent product standardization requirements, we successfully addressed the following challenges:- Demolding: The curvature of the inner core makes smooth demolding difficult in conventional casting methods.
- Deformation: During vulcanization, the ABS inner hole is susceptible to deformation, adding to production complexity.
Our solution
Through extensive research and numerous experiments, we achieved a breakthrough in mold development by creating an innovative push-pull mold design based on the number of cut corners. This distinctive approach effectively resolves the demolding issue and significantly enhances production efficiency.
Additionally, by precisely controlling vulcanization temperatures and securing the inner core during the vulcanization process, we successfully addressed the problem of ABS thermal deformation, ensuring the product’s dimensional accuracy.
Lastly, to maintain uniformity in hardness and color, we implemented a comprehensive batching method and small barrel packaging of raw materials, ensuring the quality stability of each product batch with meticulous operational procedures.
Results
Thanks to our persistent efforts, the collaboration with INDSATSEN ApS has delivered outstanding outcomes. Our product yield rate surpassed 90%, far exceeding customer expectations.
