New Energy Plastic Parts: Success Cases
From Materials · Molds · Injection Molding · Process — Achieving High Performance & Reliability for New Energy
Material Engineering
Premium materials selected to meet high voltage, flame retardant and weather resistance requirements
Mold Technology
High-precision mold design ensuring dimensional stability and mass production consistency
Injection Molding
Advanced injection molding with strict process control for reliable part performance
Quality Assurance
Full-process quality control, passing UL, IEC and other industry certifications
01 / 05
Waterproof Connector
High Sealing, High Insulation, Corrosion Resistant
Waterproof connector for new energy applications, requiring IP67/IP68 sealing, high insulation performance, corrosion resistance and long-term reliability in harsh environments.
Material
- PA6 GF30% / CTI 600V
- UV stabilized, weather resistant
- High insulation performance
- UL94 V-0 @0.8mm
Mold
- Precision mold with slide core
- Mold steel: S136
- Key dimensions: ±0.03mm
- Mold life: ≥1M cycles
Injection
- Machine: 160T
- Drying: 85°C / 4-6H
- Mold temp: 110-120°C
- Cavity pressure monitoring + SPC
Key Results
Waterproof Rating IP68
Precision ±0.05mm
Insulation Resistance >500MΩ
Yield Rate 99.6%
02 / 05
Photovoltaic Connector
UV Resistant, Weatherproof, High Insulation
Photovoltaic connector for solar energy systems, requiring exceptional UV resistance, weatherproof sealing, high electrical insulation and long-term outdoor reliability.
Material
- PA66 GF30% UV Stabilized
- CTI 600V, UV resistant
- Weatherproof: -40°C ~ +125°C
- UL94 V-0 @0.8mm
Mold
- Precision multi-slide mold
- Mold steel: S136
- Key dimensions: ±0.03mm
- Mold life: ≥1M cycles
Injection
- Machine: 160T
- Drying: 85°C / 4-6H
- Mold temp: 110°C
- Clean room: ISO Class 8
Key Results
UV Aging 2000h No Change
Precision ±0.03mm
Dielectric Strength 6kV
Yield Rate 99.4%
03 / 05
Charging Gun Accessories
Flame Retardant, Impact Resistant, High Temperature Stable
Plastic components for EV charging gun assemblies, requiring flame retardancy, high temperature resistance, impact strength and dimensional stability for reliable long-term use.
Material
- PC/ABS FR V-0
- Impact resistant, UV stable
- Good surface finish
- UL94 V-0
Mold
- Precision mold with slider
- Mold steel: 718H
- Hot runner system
- Key dimensions: ±0.05mm
- Mold life: ≥800K cycles
Injection
- Machine: 280T
- Drying: 100°C / 4H
- Mold temp: 80-100°C
- Injection pressure: 1300bar
- SPC process monitoring
Key Results
Flame Retardancy UL94 V-0
Precision ±0.05mm
Impact Strength 10kJ/m²
Yield Rate 99.2%
04 / 05
Motor End Cover
High Temperature Resistant, High Strength, Low Deformation
Key structural component for motors, requiring high temperature resistance, high strength, and minimal deformation for precise fit.
Material
- PPS+GF40%
- High temp resistance: 240°C
- High modulus, high rigidity
- Low moisture absorption
- Low deformation, stable
Mold
- High-precision precision mold
- Mold steel: S136
- Gate position optimized
- Key dimensions: ±0.03mm
- Mold life: ≥600K cycles
Injection
- High-temp injection process
- Machine: 280T
- Mold temp: 150-160°C
- Injection pressure: 1600bar
- SPC process monitoring
Key Results
Heat Resistance 240°C
Precision ±0.02mm
Deformation ≤0.15mm
Yield Rate 99.3%
05 / 05
Charging Gun Housing
Flame Retardant, Impact Resistant, UV Stable
The charging gun housing requires flame retardancy, impact resistance, weather resistance and excellent tactile feel.
Material
- PC/ABS FR
- Flame retardant V-0
- Impact resistant, UV stable
- Excellent surface finish
- UL94 V-0
Mold
- Two-shot / overmold mold
- Mold steel: 738H
- Two-shot injection process
- Key dimensions: ±0.05mm
- Mold life: ≥800K cycles
Injection
- Two-shot injection molding
- Machine: 160T
- Mold temp: 70-90°C
- Overmold hardness: Shore A 60
- Surface finish: SPI-A2
Key Results
Flame Retardancy UL94 V-0
Impact Test 1.5m No Crack
UV Aging 1000h No Change
Yield Rate 99.5%
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