Injection Molding
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PSU Insert Molding
Problem Phenomenon
PSU metal insert products show poor interfacial bonding and stress cracking; failure after thermal cycling.
Cause Analysis
Thermal expansion difference between PSU and metal; insufficient insert preheating; molding stress concentrates at the interface; thermal cycling stress accumulates.; During on-site troubleshooting, verify item by item according to this mechanism, avoiding blindly adjusting the machine based solely on experience
Solution
①Fully preheat inserts; ②Mechanical interlock design at the interface; ③Low-stress molding; ④Thermal cycling verification.; After adjustment, continuously sample to verify the effect, and resume mass production only after confirming stability
Key Takeaway
PSU insert parts require management of thermal expansion mismatch; preheating and interlocking are standard means; cyclic verification exposes long-term risks.; After confirming effectiveness, solidify the parameters and practices into the work instructions to prevent recurrence
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