SCF Microcellular Injection Molding Turnkey Line
Integrated Foaming Machines | Specialized Molds |
Full Auxiliaries | Seamless from Planning to Production
SCF Microcellular Injection Molding Turnkey Line
Are you looking to quickly transform microcellular foaming technology into productive capacity?
DKM’s microcellular injection molding turnkey line is your ideal choice. We provide not just a machine, but a complete production system—from the core microcellular injection molding machine to specialized molds, auxiliary equipment, and even plant planning and personnel training. DKM handles everything for you, ensuring you achieve large-scale production with microcellular technology in the shortest time and with minimal risk.
SCF Microcellular Turnkey Line Core Components
DKM’s turnkey line is centered around SCF microcellular foaming technology, integrating three key modules.
1. Microcellular Injection Molding Machine
Designed specifically for the supercritical fluid process, meeting the special requirements of microcellular foaming:
Specialized Screw & Barrel
Achieves a length-to-diameter ratio of 28:1, ensuring thorough mixing of nitrogen and melt to form a homogeneous single-phase melt.
High-Precision Nitrogen Injection System
Precisely controls the injection volume of supercritical nitrogen, ensuring uniform and fine cell structure (10-200μm).
Shut-Off Nozzle & Front Non-Return Valve
Prevents melt backflow, maintains injection pressure, and ensures all gas-laden melt is pushed into the mold cavity.
High-Speed Injection Capability
Completes injection within 3 seconds after plasticizing, preventing nitrogen loss and ensuring foaming quality.
Reduced Clamping Force Requirement
Injection pressure can be reduced by 40-50%, allowing larger products to be produced on smaller-tonnage machines.
2. Specialized Microcellular Mold
Microcellular foaming has unique requirements for mold design. SINOMOULD, a specialized mold manufacturer within the same group, provides design and manufacturing:
Optimized Gate Design
Gate positioned at the thinnest section of the part to ensure balanced melt flow.
Enhanced Venting System
Vent depth increased by 50% compared to traditional molds, allowing gases to escape smoothly and preventing backpressure from affecting bubble growth.
1:1 Rib-to-Wall Ratio Design
Rib thickness can reach a 1:1 ratio with the main wall thickness without sink marks, achieving higher structural strength.
Mold Temperature Control System
Combined with RHCM rapid heating/cooling technology to improve surface quality.
Mold Opening Stroke Control
Optimized for the foaming process requirements, ensuring parts are ejected after sufficient foaming.
3.MuCell Auxiliary Systems
Supercritical Nitrogen Generation & Control Unit
Provides stable, pure supercritical nitrogen with pressure control accuracy of ±0.1MPa.
Mold Temperature Controller & Chiller
Precisely controls mold temperature, ensuring stable bubble growth and formation.
Automated Part Removal & Conveying System
Enables unmanned production, improving efficiency.
SCF Microcellular One-Stop Service Process
DKM’s turnkey service covers the entire project process, allowing you to focus on your product while we handle the rest.
Phase 1:
Consultation & Planning
- Product Analysis & Feasibility Assessment: Evaluate weight reduction potential (20-30%) and cycle time reduction potential (15-40%).
- Capacity Planning & Production Line Layout: Design the optimal layout based on your factory conditions.
- Return on Investment Analysis: Clearly demonstrate the benefits of energy savings, weight reduction, and efficiency gains.
Phase 2:
Equipment Integration
- Microcellular Injection Molding Machine Customization: Select tonnage, injection volume, and screw configuration based on the product.
- Specialized Mold Design & Manufacturing: In-house mold team ensures process matching.
- Auxiliary System Integration: Nitrogen unit, temperature control equipment, and automation system provided as a one-stop package.
Phase 3:
Installation, Commissioning & Training
- On-Site Installation & Process Commissioning: Ensure the production line meets design specifications.
- Operation & Maintenance Training: Your team masters the core essentials of the microcellular foaming process.
- Trial Production Support: Assist in completing the first batch of product production, ensuring a smooth transition.
Phase 4:
After-Sales Service
- 24/7 Technical Support: Responding to your needs anytime.
- Process Optimization & Upgrades: Continuously optimize production line performance as technology evolves.
- Spare Parts Supply: Genuine spare parts guarantee continuous operation of the production line.
SCF Microcellular Turnkey Line Advantages
One-stop service reduces the time from contract signing to production startup by 50%.
Rapid Production Startup
Collaborative design of equipment, mold, and process ensures foaming quality.
Process Assurance
A single supplier responsible for all aspects avoids interface issues.
Minimized Risk
comprehensive solution reduces total investment costs and shortens the payback period.
Optimal Cost
Modular design supports future capacity expansion.
