Ultrasonic Sensor Fixing Ring CNC Machining Precision Injection Molding Shockproof Structure Manufacturing Process

This case study details the batch manufacturing process of an ultrasonic sensor fixing ring for a branded cleaning robot. The client required components with extremely high dimensional consistency, excellent impact resistance, and long-term environmental durability. We successfully met all technical specifications by employing a combined process of "Precision Injection Molding + Post-processing CNC Machining".

1. Mold Design & Manufacturing: Based on 3D drawings, the mold base was machined using 718H mold steel. The gating system and cooling channels were optimized to ensure material flow balance and uniform cooling, reducing internal stress and deformation.
   
2. Precision Injection Molding: A Haitian 120T injection molding machine was used with Bayer flame-retardant ABS material. Barrel temperature (220-245°C), injection pressure (80MPa), and holding time were strictly controlled to ensure full parts without shrinkage.
   
3. Gate Cutting & Stress Relief: After demolding, robots automatically cut the gates. The parts then underwent annealing in a constant temperature oven to eliminate internal stress and ensure long-term dimensional stability.
   
4. CNC Precision Machining: A Brother Speedio high-speed drilling and tapping center was used for precision milling and tapping of critical mounting holes. Custom fixtures achieved a positioning accuracy of ±0.01mm, guaranteeing the position and perpendicularity of all threaded holes (M3*0.5).
   
5. QC & Packaging: Products underwent full inspection for appearance (no flash, no scratches). A Coordinate Measuring Machine (CMM) was used to verify the dimensions of first articles and sampled parts. Qualified products were individually packaged in anti-static bags before storage and shipment.
   

• Process-Guaranteed Precision: The combined process ensures micron-level hole accuracy and excellent structural consistency.
• Stable Material Performance: Selected engineering plastics and strict injection molding parameters guarantee the mechanical properties of mass-produced parts.
• High-Volume Production Capacity: The optimized process enables stable output exceeding 10,000 pieces per day (single shift).

This manufacturing process is suitable for plastic structural components requiring high dimensional accuracy and stability, particularly in industries like robotics, drones, and precision instruments.

We can provide full processing solutions from mold design and material selection to mass production based on your product requirements.

We offer processing consultancy, DFM (Design for Manufacturability) reports, and sample prototyping services to ensure your product transitions smoothly from design to production.