Low Volume – Short Run Productions
Ebyton Engineers can quickly make Master Patterns and within a few days can make Silicone Molds to be used for casting PU products. Compared to Plastic Injection Molding, Vacuum Casting can save time and money. The life of the Silicone Mold is directly related to the complexity of the part being cast. Silicone Molds will generally produce 15 to 30 parts before Degradation. Average cure times: (1 to 4 hours for small parts and 4 to 8 hours for big parts).
Material Choices
Our material selection includes: HEI-CAST and PELNOX from Japan, and AXSON from France. The properties of the Thermoset Plastics are similar to engineering plastics: ABS, PMMA, PC, PP, PE, PA, POM, and others. We offer transparent, translucent, and opaque materials in a variety of different Shore Durometers and colorations. We also offer High Impact, High Temperature (150 degree) Fire Resistant UL94-V0 rank materials, and Glass Filled materials.
Size Stability & Precision Details
Our Silicone Molds provide excellent chemical stability and minimal shrinkage allowing fine details to transfer from the Master to the Mold. We use standardized operational procedures to assure the best precision and mechanical properties of the parts and control all operational parameters of each process from material mixing, de-gassing, stirring, preheating, injection, to the solidification of resin / rubber toprovide a standard precision of ±0.15mm/100mm, and the highest precision of ±0.05mm.
Molding of Big Size Parts
The maximum volume of our Vacuum Casting Machine is: (2.0m x 1.2 m x 1.0m).Ebyton provides Low Volume Short Run Productions of instrument boards, door panels, as well as automotive interiors and exteriors. The Size Precision of all parts are controlled to ±0.2mm positioning accuracy and the Locating Hole, ±0.4mm positioning accuracy of the mounting hole. The parts can meet the durability requirements of a 10,000km road test.
Low Volume Pre-production of Complex Designs
At Ebyton, innovative and creative efforts are always ongoing so that we can find better ways to improve our production processes. At Ebyton we implement many successful Mold making techniques and PU Casting process that are recognized by our clients.
A. Over Molding is a production process that uses multiple materials to make one cast part. Typically soft PU material is cast around hard PU material to make one part with two different Durometers and Colors.We can also Over Mold Transparent Parts into Opaque parts. Through this process we can make Hand Held products and Electronic Devices that meet Vibration Minimizing and Water Resistant requirements.
B.Inserting Metal Parts is a process where PU material is cast over a metal part that is placed in the mold cavity to make an In-mold Assembled Part.Both Metal Parts and Brass Inserts can be used in Over Molded to improve the mechanicalstrength and usability of parts with functional requirements.
C. Melt Molding is a process where Wax or Low Melt Temperature Alloys are used to create a mold core that is then placed inside the cavity of a second mold to be Over Molded. After being Over Molded, the mold core is then melted out of the cast part. Through this process, we can make complex parts such as radiator pipes and corrugated tubing.
D. Melt Molding is a process where Wax or Low Melt Temperature Alloys are used to create a mold core that is then placed inside the cavity of a second mold to be Over Molded. After being Over Molded, the mold core is then melted out of the cast part. Through this process, we can make complex parts such as radiator pipes and corrugated tubing.
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