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SMC Wall Panel Mold

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Product Introduction

SMC wall panel molds are thermosetting composite compression molds used to press SMC sheet molding compound under high temperature and pressure into waterproof wall panels for bathrooms, container cabins, hotel integrated bathroom systems, and exterior decorative wall panels. These panels feature a Class A smooth surface finish, reinforced ribs on the back, waterproof and flame-retardant properties, and excellent dimensional stability.

I. Overall Structure of the Mold

1. Upper and lower mold cavities (core forming components)

· patrix：

On the front surface of the formed wall panel, it is treated with mirror polishing and chrome plating. This enables the application of film transfer textures and pure color high-gloss surfaces. The surface roughness is Ra ≤ 0.4 μm, providing anti-sticking and easy demolding properties.

· counterdie：

On the back of the formed wall panel, there are designed longitudinal and transverse reinforcing rib grooves, which form an integrated reinforcing rib, enhancing the bending resistance of the wall panel. Installation pins and connection slots can be reserved for installation and connection purposes.

2.temperature control system

· The two main heating methods:

· Oil circulation heating: The temperature control is uniform with an accuracy of ±3 to 5℃. It is suitable for mass production of large-sized wall panels (1200×2400mm, 1500×3000mm).

Electric heating rod heating: Low investment cost, suitable for small and medium batch, and small and medium-sized specification molds. Standard molding temperature: 140~160℃.

3. Directional positioning + Exhaust system

Four sets of precise guide columns and guide sleeves ensure that the large flat plate does not deviate during the closing process, and the flying edge is controlled to be ≤ 0.1mm;

Micro-exhaust grooves are set around the cavity + optional vacuum exhaust, which helps avoid air bubbles, material shortages, and surface pinhole defects in the sheet material.

4.mold emptier

Using pneumatic ejection and a multi-point pin layout, large-sized wall panels are prevented from warping and deformation, ensuring the flatness of the panels during demolding.

II. Selection of Common Mold Materials (Based on Production Lifespan)

die steel

Heat treatment hardness

Estimated cycle life

applicable scene

P20/718H

HRC32~38

300,000 to 500,000 mold cycles

Small and medium-sized batches of conventional civilian wall panels, the best choice for cost-effectiveness

2738

HRC34~40

500,000 to 800,000 mold cycles

High-frequency mass production, export orders, A-level appearance requirements

H13 Heat Treatment Steel

HRC48~52

800,000 to 1,000,000 + batches

Large-scale press machine, high-pressure mass production, long-term continuous production

surface treatment：

Cavity mirror surface polishing + hard chromium electroplating 5-10 μm. It is wear-resistant, corrosion-resistant, and can be repeatedly demolded without scratching the paint surface.

III. Regular Process Parameters and Production Flow

1.Core parameters for shaping

Mold forming pressure: 800 - 2000T hydraulic compression press

· Mold temperature: 145 - 155℃

· Holding and curing time: 120 - 200 seconds

· SMC material feeding: Cutting, weighing, and laying materials, and it can simultaneously place heat transfer decorative films. The decorative surface is not peeled off during one-time molding.

2. Complete production process

1. Preheat the mold and apply internal/external demolding agents to the cavity.

2. Cut the SMC sheet, precisely weigh and place it into the mold, then attach the decorative film.

3. Close the mold → Lock the mold under high pressure → Maintain constant temperature and apply pressure for curing.

4. Open the mold and use pneumatic actuators to push out the parts at multiple points for demolding.

5. Trim the wall panel edges, remove burrs, inspect and store.SMC模压成型原理

IV. Key Design Points of SMC Wall Panel Molds

1. Draft：

The inclination of the plate is greater than 1°, and the position of the reinforcement bars is greater than 1.5°. This is to prevent the plate surface from being pulled apart and to avoid the reinforcement bars from breaking.

2. Strengthening rib layout：

Interwoven grid reinforcement bars, with the bar thickness generally being 0.8 times the thickness of the wall panel, not only reduces weight but also prevents deformation. After cutting, the installation position of the reinforcement bars is still retained.

3. Uniformity of wall thickness：

The conventional thickness of the wall panels is 3 to 5 mm. The thickness difference should be controlled within 0.5 mm to avoid uneven curing and warping in certain areas.

4. Type surface design：

Adopt a planar parting method, combining four-side overflow channels and exhaust channels to control burrs and reduce the workload of subsequent trimming operations.

5. Integrated pre-installed nut inserts are available. During the pressing process, the threaded holes are directly formed for easy installation without the need for subsequent drilling.