Zinc Alloy Housing Overmolding LSR Liquid Silicone Encapsulation and Insert Molding
FEATURES
The “Hard Power” Foundation — Building Customer Trust Through Infrastructure
Why this matters to you: Before we discuss design specifics, we want you to understand the physical manufacturing capability that backs every promise we make.
Precision Mold Manufacturing Equipment
At Ansix Tech, we believe that world-class output requires world-class input. Our mold manufacturing workshop is equipped with advanced machining centers that directly impact your product quality and time-to-market:
Equipment Type Technical Specification Customer Value
Five-axis high-speed machining centers 0.002mm precision capability for complex curved surfaces Your product‘s parting lines remain smooth and burr-free, eliminating costly secondary finishing operations
Slow wire EDM (Electrical Discharge Machining) Capable of producing 0.03mm fine micro-holes and narrow slots Thin-walled sections around inserts remain distortion-free, preventing assembly failures
High-speed CNC machining centers Multiple units operating around-the-clock Reduced lead times without compromising quality
EDM machining workshop Self-contained electrode production and spark erosion Tool modifications happen in-house — no outsourcing delays
Our philosophy is simple: every piece of equipment is selected based on one criterion — how it benefits you, our customer.
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Mold Description
Product Materials:
Zinc Alloy +LSR SILICONE
Soft rubber: LSR silicone
Mold Material:
S136ESR
Number of Cavities:
2
Glue Feeding Method:
Hot runner
Cooling Method:
Water cooling
Molding Cycle
22.5s
- The mold manufacturing process and product material selection
Injection Molding Machine Fleet
We operate 260 injection molding machines with clamping forces ranging from 30 tons to 2,800 tons, covering the complete spectrum of product sizes from micro-precision components to large-format housings. Our machine park includes:
Japan‘s FANUC, Sumitomo, Toshiba, Nissei
Germany’s ENGEL and ARBURG (specializing in liquid silicone rubber two-component injection molding)
China‘s Haitian and Victor Taichung Machinery
All machines are equipped with full-servo electric drives, delivering stable repeatability with ±0.1% precision. This means every shot produced today matches every shot produced next week — batch-to-batch consistency that protects your downstream assembly lines from unexpected variation.
Why our machine park matters to you: Whether you need micro-dosing of LSR for a tiny medical seal or high-pressure injection for a large automotive housing, we have the right machine for your project. No “one-size-fits-all” compromises.
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Inspection and Quality Assurance Equipment
Every mold we manufacture and every part we produce undergoes rigorous inspection:
Equipment Application Your Benefit
Coordinate Measuring Machines (CMM) Full dimensional inspection of molds and production samples Every mold ships with a complete dimensional report — no guesswork
Optical imaging systems High-speed measurement of complex geometries Rapid verification of critical features
Vision inspection systems Automated surface defect detection Consistent quality without human fatigue
Commitment: Every mold undergoes full dimensional report comparison before shipment, with critical dimensions achieving Cpk ≥ 1.33 — a statistical guarantee that your production will remain stable within tolerance.
Section II: Mold Manufacturing Core Competencies — Speaking the Language of Customer Value
Why this matters to you: Your mold is the engine of your production line. We translate technical specifications into guarantees that protect your investment.
2.1 Mold Life and Durability
We don‘t just tell you our mold materials; we tell you what they mean for your production uptime:
Mold Component Material Industry-Standard Specification Ansix Commitment
Mold base P20 Pre-hardened, good machinability Structural integrity for 500k+ cycles
Mold core/cavity (standard) S136 stainless steel Hardened to 48-52 HRC, corrosion-resistant 1,000,000+ cycles for general plastics
Mold core/cavity (abrasive-filled resins) H13, 2344, 8407, SKD61 Hardened to 46-54 HRC, wear-resistant 500,000+ cycles for glass-fiber reinforced materials
Mold core/cavity (high-polish/corrosive) M340, 4Cr13, 9Cr18 Superior corrosion resistance and mirror finish Extended life for medical/optical applications
Mold core/cavity (tight-tolerance) NAK80, DC53 Pre-hardened, high hardness, excellent polishability 0.005mm precision retention for 300k+ cycles
H13 steel, when vacuum-quenched and tempered to HRC 46-54, resists abrasive wear from glass-filled resins approximately 3× better than standard P20 — a critical advantage when running glass-reinforced engineering plastics. For applications requiring maximum corrosion resistance or mirror-finish retention, S136 stainless tool steel (13%+ chromium content) is the industry benchmark for maintaining dimensional stability under extreme thermal stress.
What this means for you: Every mold is accompanied by material certification reports and heat treatment curves — complete documentation that protects your quality chain.
2.2 Achievable Tolerances
Part Type Standard Tolerance Precision Tolerance
General structural components ±0.05mm ±0.02mm
Precision gears, medical components N/A ±0.005mm
Critical mating features ±0.02mm ±0.01mm
For zinc alloy die-cast components, we consistently achieve tolerances of ±0.01mm on critical dimensions — the precision required for high-IP-rated sealing surfaces.
2.3 Mold Type Capabilities
Our mold engineering team designs and builds:
Hot runner systems — Reduce material waste by eliminating runner scrap; particularly valuable for expensive engineering resins and LSR
Multi-cavity molds — Up to 64+ cavities for high-volume production
Family molds — Multiple part geometries in a single mold
Two-shot / multi-material molds — For simultaneous molding of rigid substrate and LSR overmold
High-gloss mirror finish molds — Surface roughness Ra < 0.05μm, essential for optical-grade transparent components
Insert molds — Precision positioning systems for metal insert encapsulation
2.4 Gating and Runner System Optimization
We use advanced mold flow analysis (CAE) to predict weld line locations, air trap positions, and flow imbalances before steel is cut. This predictive capability allows us to:
Optimize gate locations and quantities for balanced cavity filling
Minimize weld lines in cosmetic surfaces
Eliminate short-shot risks
Reduce the number of mold iterations needed for stable production
For LSR applications specifically, we employ cold runner systems (cold decks) where the runner is maintained at low temperature to prevent premature curing, while the cavity is heated to 150-200°C for crosslinking. This approach eliminates runner waste entirely — a direct material cost saving that compounds over millions of cycles.
2.5 Standard Mold Delivery Lead Times
Mold Complexity Standard Lead Time Expedited (with validation)
Simple molds (low cavitation, basic geometry) 15-20 days As low as 10 days
Medium complexity 25-35 days 20-25 days
High complexity (multi-cavity, hot runner, complex inserts) 40-50 days 30-35 days
What we never compromise: Even under expedited timelines, we never skip validation steps. Faster delivery does not mean lower quality.
Section III: Injection Molding Process Control — Eliminating Your Quality Anxiety
Why this matters to you: Your biggest fears — sink marks, flash, dimensional drift, batch-to-batch color variation — are exactly the problems we‘ve systematized to prevent.
3.1 Process Standardization and Digital Traceability
All 260 injection molding machines are networked to our Manufacturing Execution System (MES). Every critical processing parameter — temperature, pressure, speed, and curing time — is locked within the system and can only be adjusted by authorized engineers.
Every batch undergoes first-article and last-article inspection and comparison. If the last part of a production run doesn‘t match the first, the batch doesn‘t ship.
3.2 Dimensional Stability Control
Dimensional stability is achieved through:
Zone-controlled mold temperature regulation: Each mold is equipped with independent temperature control zones, with core and cavity temperature differential maintained within 2°C — significantly reducing thermal-induced warpage
Real-time thickness monitoring: Ultrasonic sensors continuously monitor wall thickness fluctuations and automatically trigger compensatory packing pressure adjustments
In-mold temperature and pressure sensors (optional): Enable closed-loop process control for the most demanding applications
Validation data: For similar housing components, we demonstrate that across three consecutive production weeks, critical hole-to-hole spacing variation remains ≤0.02mm — well within industry standards for even the most demanding assembly requirements.
3.3 Surface Finish and Appearance Standards
Grade Specification Typical Applications
SPI-A1 / SPI-A2 Diamond buffed — Ra < 0.012μm Optical lenses, high-gloss cosmetic surfaces
SPI-B1 / SPI-B2 Paper stone ground — Ra 0.025-0.05μm Medical device housings, consumer electronics
SPI-C1 / SPI-C2 Stone ground — Ra 0.05-0.10μm Industrial components, under-hood automotive parts
SPI-D Dry blast texture Textured grip surfaces, matte finishes
For LSR components specifically: We guarantee bubble-free, flow-line-free surfaces through optimized venting and vacuum-assisted molding systems. By implementing multi-stage precision venting systems, we eliminate trapped gas at every potential dead zone.
3.4 Advanced Engineering Material Capabilities
We possess production-proven experience with a wide spectrum of materials:
Thermoplastics:
PC, ABS, PC/ABS blends
PPS + 40% GF (glass fiber reinforced)
PEEK, PEKK (high-temperature, high-strength)
PA6 + GF30 (nylon with 30% glass fiber)
POM, PBT
PEI (Ultem®), PPS, LCP
Liquid Silicone Rubber (LSR):
Standard LSR (shore A 20-80)
Self-bonding LSR grades — eliminate separate primer application steps
Optical-grade transparent LSR — for LED lenses and light guides
Medical-grade LSR (ISO 10993 biocompatibility certified)
Low-viscosity LSR — improves filling of intricate detail
Why LSR over molding matters: The global LSR market was valued at USD 3.8 billion in 2024 and is projected to reach USD 7.1 billion by 2034, growing at a CAGR of 6.5%. The medical LSR injection molding equipment market is accelerating even faster, projected at 8.9% CAGR through 2031.
Performance guarantees:
UL94 V-0 flame rating available for electrical enclosures
UV resistance — 3,000-hour accelerated weathering with no significant color change or surface degradation
Temperature range: -50°C to +200°C continuous service
IP68 waterproof rating when properly designed — suitable for underwater equipment and outdoor sensors
LSR injection molding parameters (production-validated):
Parameter Typical Range Impact on Your Product
Barrel temperature 40-80°C (prevent premature curing) Consistent material flow, no scorching
Injection pressure 50-150 bar Fills fine details without flash
Mold (curing) temperature 150-200°C Optimized crosslinking for full mechanical properties
Injection speed 0.5-3.0 seconds fill time Prevents premature curing before cavity fills
Unlike thermoplastics, LSR‘s lower flow resistance eliminates the need for complex pressure profiling during injection — simplifying process control while delivering superior detail replication.
3.5 Insert Molding and Overmolding Capabilities
Our zinc alloy housing overmolding process addresses the two fundamental challenges of metal-encapsulation:
Challenge 1: “Bonding” — Achieving reliable adhesion between LSR and zinc alloy
Self-bonding LSR grades (selected based on your performance requirements)
Surface preparation: ultrasonic cleaning, plasma treatment, or chemical primers
The combination of surface activation, optimized adhesive-grade silicone formulation, and precisely matched process parameters creates a dual-bonding mechanism of mechanical interlock + chemical bonding
Physical roughening combined with chemical activation can increase interfacial bond strength by more than 60%
Challenge 2: “Stability” — Keeping metal inserts precisely positioned under high injection pressure
Precision fixture systems within the mold
Strategic core and cavity design to stabilize inserts
Optimized gate placement to minimize flow-induced displacement
Quantifiable result: For a zinc alloy insert project, switching to low-viscosity LSR reduced void/bubble rates from 15% to 2.3%, while fill time decreased from 8 seconds to 3.5 seconds.
Section IV: End-to-End Service Integration — Reducing Your Total Cost of Ownership
Why this matters to you: Your management costs — procurement coordination, supplier qualification, quality validation — are often hidden but substantial. We systematically eliminate them.
4.1 Early Engagement: Design for Manufacturability (DFM) Analysis
Before you commit to mold fabrication, our engineering team provides a comprehensive DFM report that includes:
Analysis Component What We Deliver Your Benefit
Draft angle recommendations Optimal angles for clean part ejection Prevents sticking, eliminates ejection damage
Wall thickness optimization Uniformity analysis with specific recommendations Reduces sink marks, minimizes warp, can reduce material consumption by up to 25%
Gate location optimization Simulation-validated gating strategy Balanced filling, reduced weld lines
Ejector pin mark placement Strategic placement analysis Prevents cosmetic surface defects
Material selection consultation Trade-off analysis across cost, performance, availability Informed decision-making with no surprises
By using advanced mold flow simulation (CAE) to virtually simulate the injection process before production begins, our engineers optimize gate locations and predict filling behavior long before steel is cut. This predictive capability directly translates into customer cost savings.
Case study reference: Using mold flow analysis validation, one project reduced material content by 25% while maintaining dimensional requirements, reduced the number of mold trials, and lowered production costs — with a documented 67% reduction in manual labor costs.
4.2 Trial Molding and Sample Delivery — T0 through T3
We don‘t just send you a mold and disappear. Our iterative validation process:
Stage Deliverable
T0 — First shot Bare mold trial; initial samples with preliminary inspection report
T1 — First adjustment Mold modifications based on T0 findings; updated samples with full dimensional report
T2 — Fine-tuning Cosmetic and dimension optimization; process parameter windows established
T3 — Pre-production validation Full validation before production release
What this means for you: Every iteration is documented with an improvement report. We can quickly exchange mold inserts to validate different design approaches without rebuilding an entire mold — protecting your project budget.
4.3 Low-Volume Pilot Production
Before committing to high-volume production, we offer 100-500 shot pilot runs that provide:
Statistical yield and Cpk analysis across the pilot batch
Process stability verification
Production readiness confirmation
Identified optimization opportunities
Your risk reduction: You approve full-scale production only after we have statistically demonstrated that your process is ready.
4.4 Maintenance and Spare Parts Program
We deliver long-term production reliability, not just a one-time shipment:
Service Component Description
Spare parts kit Wear parts (ejector pins, core pins, wear plates) delivered with the mold
Maintenance schedule Documented preventive maintenance intervals (recommended: every 200,000 cycles)
Lifetime repair support Cost-plus pricing for repairs; no premium surcharges
4.5 Vertical Integration — A Resilience Blueprint
Ansix Tech maintains four manufacturing facilities across China and Vietnam. Our vertically integrated approach — encompassing prototyping, mold manufacturing, injection molding, and final assembly validation — provides a blueprint for supply chain resilience.
What this means for you: You have a single point of accountability for your entire program. No finger-pointing between separate mold shops and molding houses. No logistics coordination headaches.
Section V: Differentiated Value Proposition — Addressing Industry Pain Points Head-On
Why this matters to you: Rather than telling you how good we are, we address the specific problems you‘ve likely experienced with other suppliers.
Industry Pain Point The Typical Experience The Ansix Tech Solution Quantifiable Commitment
Frequent mold repairs disrupting production Mold fails after 100k cycles; you scramble for repairs while production stops Pre-delivery 2,000-cycle aging test; wear report delivered with mold; three-year structural warranty (excluding normal wear parts) Assured productivity: No unexpected downtime from premature mold failure
Flash — high post-molding finishing costs Flash requires manual trimming, adding labor cost and risking part damage 0.005mm parting line fit tolerance; self-locking clamp force compensation system; flash controlled to ≤0.03mm per batch No manual finishing: Parts ship ready to use
Dimensional instability batch-to-batch First batch fits assembly; second batch doesn‘t; you hold shipments for inspection All machines networked to MES with locked parameters; real-time thickness feedback with automatic compensation; optional in-mold sensor closed-loop control Guaranteed interchangeability: Parts from any batch assemble without rework
Long mold repair lead times Mold repair requires sending out to third-party shops; you‘re down for 2-4 weeks In-house electrode manufacturing and EDM workshop; mold repairs never leave our facility; standard repair: 24-hour turnaround for weld repairs/insert replacements Minimized downtime: Production interruption measured in hours, not weeks
Hidden costs from design flaws discovered after mold build You sign off on design; mold built; first shots reveal un-moldable features; expensive rework Pre-contract DFM analysis identifies every risk — draft angles, wall thickness, gate placement, ejector pin location — before steel is cut “Right first time”: No costly post-mold design changes
Quality documentation gaps in regulated industries You struggle to compile material certs, inspection reports, process validation documentation for audits ISO 13485:2016 certified systems; full material traceability; documented IQ/OQ/PQ process validation; Cpk ≥ 1.33 on all CTQ dimensions; eDHR system integration for complete lot traceability Audit-ready documentation: Every shipment includes complete quality records
For medical device applications specifically: Ansix Tech operates as an ISO 13485:2016 certified manufacturer with extensive experience in medical product design, mold engineering, and precision injection molding. We support ISO 10993 biocompatibility requirements, full sterilization compatibility (EtO, gamma, steam), and complete lot traceability.
For automotive applications: Zinc alloys provide excellent electrical conductivity and natural EMI/RFI shielding properties — critical for protecting sensitive electronics in autonomous driving sensors, LiDAR housings, and ECUs. Overmolded LSR provides vibration damping and IP-rated sealing for connectors and cable grommets.
Section VI: Technical Deep Dive — Zinc Alloy Housing LSR Overmolding by Process Stage
For engineers who demand the technical details: Here is the complete process flow.
6.1 Zinc Alloy Substrate — Material Selection and Properties
Zinc alloys (typically ZAMAK 2, 3, or 5) are selected for:
Property Specification Benefit
Melting point 380-420°C Lower than aluminum die casting (600-700°C), reducing energy and equipment requirements
Fluidity Excellent Enables thin-wall (0.5-1.0mm) precision die casting with intricate detail
Die casting cycle rate 150-200% faster than aluminum Higher productivity from the substrate manufacturing stage
Corrosion resistance Excellent Long-term durability in harsh environments
EMI/RFI shielding Natural shielding properties Protects sensitive electronics without secondary coatings
Dimensional stability ±0.01mm achievable on critical features Enables precision sealing surfaces for IP-rated assemblies
Upper service temperature Continuous: 95-120°C; Max: 150°C Suitable for most electronics and automotive under-hood applications
6.2 LSR Material Selection — Grades and Properties
Grade Application Key Characteristics
General-purpose LSR Standard seals, gaskets, bumpers Shore A 20-80, good tear strength
Self-bonding LSR Direct overmolding to metal/plastic without primer Eliminates secondary priming operation
Optical-grade LSR LED lenses, light guides, display windows High transparency, minimal haze, low birefringence
Low-viscosity LSR Thin-wall overmolding, intricate features Improved fill of complex geometry; reduces bubble formation
Medical-grade LSR Implantable and tissue-contact devices ISO 10993 certified, USP Class VI; low volatiles (<0.5%)
High-tear-strength LSR Dynamic seals, high-stress applications Extended service life under mechanical cycling
6.3 Surface Preparation — Zinc Alloy Pre-Treatment
Step Method Purpose
1 — Cleaning Ultrasonic cleaning with appropriate solvent Removes oils, coolants, and machining residues
2 — Activation (optional) Plasma treatment or chemical primer application Increases surface energy for improved wetting and bonding
3 — Pre-heating Controlled pre-heat prior to insert loading Prevents thermal shock; ensures consistent LSR curing kinetics
For self-bonding LSR grades, surface preparation requirements are minimized, but proper cleaning remains essential.
6.4 Mold Design for Insert Overmolding
Design Element Specific Consideration for Zinc Alloy Inserts
Insert positioning Precision fixturing within mold; shrink-fit or mechanical retention to prevent displacement under injection pressure
Gate placement Optimized to direct flow away from insert critical features; minimize flow-induced insert movement
Venting Multi-stage venting around insert perimeter to prevent air entrapment; critical for bubble-free encapsulation
Thermal management Independent mold temperature zones for different cavity regions; inserts often require localized cooling control
Parting line selection Strategic placement to avoid sealing surfaces or cosmetic zones
6.5 LSR Injection Molding Process Parameters
Parameter Value Critical Consideration
A:B mixing ratio 1:1 ±1% Precision metering essential for consistent cure; closed-loop control required
Barrel temperature 40-80°C Too hot → premature crosslinking in barrel; too cold → viscosity too high
Mold temperature 150-200°C (standard); 120-150°C (slow-cure applications) Affects cure time, final mechanical properties, and surface finish
Injection pressure 50-150 bar Lower than thermoplastics — enables fine detail replication without flash
Cure time Dependent on part thickness and mold temperature DOEs established during process validation; typically 10-60 seconds
Cold runner temperature 20-40°C (chilled) Keeps material fluid in runner while cavity cures; eliminates runner waste
For optical LSR applications, the hot mold is maintained between 160°C and 200°C, and most crosslinking occurs inside the heated cavity.
6.6 Quality Validation and Process Control
Our quality system is built on documented, validated processes:
Validation Stage Activity Deliverable
IQ (Installation Qualification) Machine and mold installation verification; all sensors, heaters, cooling systems verified IQ protocol document
OQ (Operational Qualification) Parameter window definition: temperature extremes, pressure limits, speed ranges Parameter window documentation; OQ protocol
PQ (Performance Qualification) Three consecutive production batches; Cpk ≥ 1.33 on all CTQ dimensions; PPAP documentation where required PQ protocol; CPK analysis; PPAP submission (on request)
In-process controls:
Real-time parameter monitoring via MES; automated alerts for parameter drift
Sampling frequency determined by part criticality and historical capability
First-article and last-article inspection for every batch
Vision inspection for surface defects on high-cosmetic applications
Regulatory alignment: ISO 13485:2016 for medical; IATF 16949 core tools with Cpk ≥ 1.67 and zero-defect PPAP submissions for automotive; full lot traceability for all regulated industries.
Section VII: Cost Control — How Ansix Tech Reduces Your Total Manufacturing Cost
Why this matters to you: Every manufacturing decision we make is evaluated through the lens of your total cost.
7.1 Material Cost Optimization
Strategy Application Typical Savings
DFM-driven material reduction Wall thickness optimization identified during DFM phase 15-25% material reduction without compromising strength
Precise cold runner systems for LSR Eliminates runner waste entirely — no material discarded between cycles 20-40% LSR material cost reduction vs. hot runner or cold sprue systems
Runner optimization for thermoplastics Hot runner systems reduce or eliminate runner scrap 10-30% material cost reduction for family or multi-cavity tools
Material substitution guidance Alternative grades with comparable performance at lower cost 10-30% material cost reduction depending on application
7.2 Cycle Time Reduction — Labor and Machine Efficiency
Strategy Application Impact
Multi-cavity mold design 2, 4, 8, 16, 32, or 64 cavities per mold Output scales linearly with cavity count; per-part cycle time effectively divided by cavity count
Family molds Multiple unique part geometries in single mold Eliminates multiple setups and multiple machines
Optimized cooling channel design Conformal cooling where applicable; strategic placement of cooling lines Reduced cooling time; faster cycles; fewer post-mold warp issues
Automated part handling Robotic part removal and conveyor delivery Reduced labor cost; consistent cycle-to-cycle timing
7.3 Secondary Operation Elimination
Problem Solution Savings
Post-molding flash removal Precision 0.005mm parting line fit; self-locking clamp force compensation Eliminates manual trimming — typically 5-15 seconds per part of labor
Post-molding deflashing Optimized gate design and placement Gates break cleanly; no secondary cutting
Assembly steps Designed-in snap fits, heat stakes, or ultrasonic welding features Reduces or eliminates downstream fastening operations
Priming for LSR overmolding Self-bonding LSR grades selected where appropriate Eliminates separate primer application station and materials
7.4 Reduced Scrap and Rework
Initiative Measurement
Process capability validation (Cpk ≥ 1.33) before production Production scrap typically <2% for stable processes
Real-time parameter monitoring with automated drift alerts Prevents extended runs of out-of-spec parts
First-article inspection for every batch Identifies issues before high-volume production continues
SPC-driven process adjustments Maintains process within validated window; prevents drift into defect territory
Section VIII: Delivery Efficiency and Supply Chain Reliability
Why this matters to you: Late deliveries disrupt your production and damage your customer relationships.
8.1 Lead Time Commitments
Service Standard Expedited
DFM analysis 3-5 business days As low as 2 days
Simple mold fabrication 15-20 days As low as 10 days
Medium complexity mold 25-35 days 20-25 days
High complexity mold 40-50 days 30-35 days
Pilot production (100-500 shots) 5-7 days after mold approval 3-4 days
Ongoing production — per shipment 2-4 weeks depending on volume and complexity Flexible expediting available
8.2 Production Capacity
260 injection molding machines — no single machine is a bottleneck
30 to 2,800 ton clamping force range — one supplier for micro-precision to large-format components
Four facilities across China and Vietnam — geographic diversification for supply chain resilience
24/7 production availability — we can scale production to meet seasonal demand surges
8.3 Vertical Integration Advantages
Because we control the entire process chain — prototyping, mold manufacturing, injection molding, and assembly verification — we eliminate handoffs that typically cause delays:
Capability In-House or Outsourced Benefit
Mold design In-house DFM and mold engineering No external design delays
CNC machining, EDM, wire EDM In-house workshop No outsourcing lead times
Electrode manufacturing In-house Mold modifications start immediately
Injection molding 260 machines in-house No waiting for third-party molding capacity
Quality inspection In-house CMM and optical systems Immediate results, no external labs
Assembly and secondary operations In-house capabilities Single-supplier finished components
Section IX: Risk Mitigation — Protecting Your Program Investment
Why this matters to you: Every manufacturing program carries risk. We systematically identify and eliminate it before it affects you.
9.1 Technical Risk Elimination
Risk Ansix Tech Mitigation Strategy
Design un-moldable Pre-contract DFM analysis identifies and resolves every manufacturability issue before steel is cut
Weld lines in cosmetic areas Mold flow analysis predicts weld line locations; gate placement optimized to move weld lines to non-cosmetic zones or eliminate them entirely
Air traps causing voids or bubbles Multi-stage venting design; optional vacuum assist during injection; mold flow validation of air evacuation
Warpage from uneven cooling Thermal analysis during mold design; zone-controlled mold temperature; conformal cooling channels where applicable
Insufficient bonding between LSR and zinc alloy Self-bonding LSR grades; documented surface preparation procedures; validated process parameters; bond strength testing per ASTM
Insert displacement during injection Precision fixturing; optimized gate placement to minimize flow forces on insert; process validation confirming position stability
10.0 Conclusion — A Partner, Not Just a Supplier
At Ansix Tech, we view every mold and every production program as a partnership. We don‘t just deliver components; we deliver production readiness, quality confidence, and cost predictability.
Our philosophy is grounded in a simple principle: a mold is not just a block of steel — it is a revenue-generating asset for your business. Every decision we make in mold design — from steel selection to gate placement to cooling channel layout — is optimized for your production line: ready-to-run, minimal flash, long service life.
What we deliver:
ISO 13485:2016 certified quality systems for medical and regulated applications
28+ years of injection molding heritage with 30,000+ molds delivered since 1998
260 injection molding machines across four facilities in China and Vietnam
Vertical integration from DFM through mold build to production and assembly
Documented process validation with Cpk ≥ 1.33 on all critical dimensions
Complete traceability from raw material to finished shipment
What this means for you:
Lower total cost — not just lower piece price — through material optimization, cycle time reduction, and secondary operation elimination
Reduced risk through DFM analysis, process validation, and documented quality systems
Faster time-to-market through parallel engineering and in-house capabilities
Peace of mind through a single-source partner accountable for your entire program
Next Step: We invite you to submit an existing product design for a comprehensive DFM analysis. During a one-hour review session, we will demonstrate in real time how we identify and resolve potential issues — weld lines, air traps, sink marks, bonding risks — before they ever reach your production line.
*Ansix Tech Limited — 28+ Years of Precision Injection Molding Excellence | ISO 13485:2016 Certified | 260 IMMs | 30T to 2800T | Four Global Facilities*
Appendix: Quick Reference — Key Capabilities Summary
Category Capability
Machines 260 injection molding machines: 30T to 2800T (FANUC, Sumitomo, Toshiba, Nissei, ENGEL, ARBURG, Haitian)
Materials PC, ABS, PC/ABS, PPS+GF, PEEK, PA6+GF, POM, PBT, PEI, LCP, LSR (all grades), medical-grade LSR
Mold steels P20 (base), S136, H13, 2344, 8407, SKD61, M340, 4Cr13, 9Cr18, NAK80, DC53
Precision ±0.005mm achievable; Cpk ≥1.33 standard
Mold life 500k-1M+ cycles depending on material and steel selection
LSR parameters 40-80°C barrel; 150-200°C mold; 50-150 bar injection pressure
Quality systems ISO 13485:2016; full traceability; PPAP; IQ/OQ/PQ validation
Delivery Simple mold 10-15 days; pilot production 3-7 days
Facilities Four locations across China and Vietnam
Ansix Tech Co Ltd
If you have any plans related to Zinc Alloy Housing Overmolding LSR Liquid Silicone Encapsulation and Insert Molding , you can contact us at any time. We will turn your ideas into reality, let you realize your dreams, and obtain large orders from the market. Our contact information is info@ansixtech.com. Or contact our CTO, mail: stephen@ansixtech.com
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