SMC Washbasin Mold
I. Basic Definitions The SMC (Sheet Molding Compound) basin mold is a specialized mold designed for the hot-curing compression molding of SMC composite material basins (washbasins or face basins). Through the application of high temperature and high pressure, the SMC sheet material fully flows...
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Product Introduction
I. Basic Definitions
The SMC (Sheet Molding Compound) basin mold is a specialized mold designed for the hot-curing compression molding of SMC composite material basins (washbasins or face basins). Through the application of high temperature and high pressure, the SMC sheet material fully flows and fills the mold, completing cross-linking and curing to form a basin product with precise dimensions and a smooth surface. Compared to traditional ceramic basins, SMC basins offer advantages such as light weight, excellent impact resistance, and controllable molding cycles, making them suitable for large-scale batch production.
II. Core Structural Components
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assembly unit |
Material/Selection |
Function and Design Key Points |
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Formwork + Formwork panel |
P20/718H (medium batch production), H13 (large batch production / high-temperature conditions) |
The high rigidity web plate design is adopted to effectively prevent the mold from deforming during high-pressure molding. The hardness of the template should reach HRC 48–52, and it should undergo nitriding or quenching treatment to enhance the overall durability of the mold. |
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Mold cavity and core |
2316 stainless steel or high-quality die steel, with the surface treated by mirror polishing and hard chrome electroplating process |
The shape of the basin and the A-level surface quality are directly determined by this. The demolding angle must be strictly controlled, with the fixed mold angle being ≥ 3° and the moving mold angle being ≥ 5°. This is to prevent defects such as scratches and marks from occurring during the product demolding process. |
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heating system |
Oil can be heated by either oil or electric means, and it supports independent temperature control for multiple zones. |
The molding temperature should be controlled within the range of 140–160℃, with the temperature difference in each area being no more than ±3℃. This ensures the uniform curing of the SMC sheet and guarantees the stable quality of the product during the molding process. |
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exhaust air system |
0.01–0.03mm micro exhaust grooves, combined with vacuum-assisted exhaust structure |
Efficiently remove the volatile gases generated during the curing process of SMC sheets, thereby preventing the occurrence of quality defects such as pinholes and bubbles on the product surface. |
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mold emptier |
Hydraulic push rod + air-assisted ejection combined structure, avoiding concentrated force at a single point |
The lifting position should be avoided from the visible surface of the product to maximize the protection of the surface finish of the basin and prevent any scratches caused by the lifting process. |
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Insertion device |
Positioning pin + anti-rotation limit structure |
Realize the integration of the threaded sleeve, metal flange and other inserts with the basin body, thereby enhancing the assembly efficiency and structural stability of the product. |
III. Key Design and Manufacturing Technologies
1. CAE Simulation Leading: Utilizing the mold flow analysis technology, we can accurately predict the flow path of the SMC sheet, the distribution of fiber orientation, optimize the mold parting surface, gate position, and exhaust system location, effectively preventing forming defects such as short shots, fiber accumulation, and air holes.
2. Surface treatment: The surface of the mold cavity must meet the mirror-polished standard of Ra 0.02–0.05 μm. Subsequently, hard chromium electroplating (with a coating thickness of 0.03–0.05 mm) or PVD coating treatment will be carried out to ensure both the wear resistance and the smooth demolding performance of the mold surface.
3. Tolerance and shrinkage control: The shrinkage rate of SMC material during molding is 0.2% - 0.5%. During the mold design stage, precise shrinkage compensation must be carried out; the flatness of the basin surface needs to be controlled within ≤ 0.5mm/1000mm, and the edge radius should be set as R ≥ 1mm to prevent the product from experiencing stress cracking.
4. Processing Technology: Utilize CNC five-axis linkage processing technology to precisely shape the cavities, and combine EDM (Electrical Discharge Machining) for fine refinement of narrow slots and deep cavities with complex structures; the heat treatment adopts vacuum quenching + deep cold treatment processes, significantly enhancing the hardness and service life of the molds; after the mold assembly is completed, a trial mold debugging is required, and the forming parameters such as temperature, pressure, and holding time are iteratively optimized to ensure the stability of mass production.
IV. Standard Forming Process
1. Pre-treatment: Heat the mold to 145 ± 5℃, and cut the SMC sheet according to the weight of the basin mold, and preheat and soften the sheet to facilitate subsequent mold filling.
2. Mold closing and pressurization: Place the preheated SMC sheet into the mold cavity, close the mold and apply a forming pressure of 15–30 MPa to ensure that the sheet is fully adhered to the mold cavity.
3. Thermal insulation and pressure retention: Maintain the mold temperature and the forming pressure. Insulate and retain the pressure for 3 to 8 minutes (the specific duration can be adjusted flexibly according to the thickness of the basin wall), allowing the SMC sheet material to fully cross-link and cure.
4. Demolding and Cleaning: Release the pressure and open the mold. Use the demolding mechanism to push out the formed basin product. Immediately clean the remaining resin on the mold cavity surface to prepare for the next mold production.
5. Post-processing: Trim and polish the basin after it is ejected, remove any excess material edges and surface flaws. If necessary, perform surface spraying or glazing treatment to enhance the appearance and texture of the product.
V. Quality Control and Lifespan Maintenance
✬Common Defects and Causes: Air holes (poor exhaust system or uneven temperature of the mold/stock sheet), surface flow marks (low temperature of SMC sheet or mold, insufficient flowability), warping (large temperature difference in each area of the mold during curing, uneven shrinkage).
✬ Mold life: The molds are made of high-quality H13 steel and treated with hard chrome coating. Their service life can reach 100,000 to 300,000 mold cycles, which can meet the requirements of mass production.
✬Key points for daily maintenance: After each production session, the mold cavity should be cleaned with a dedicated cleaning agent to prevent resin residue from accumulating; regularly inspect components such as heating tubes, seals, and push rods, and replace damaged parts in time to prevent leakage or jamming; during the long-term inactivity of the mold, oil sealing treatment should be carried out and rust protection measures should be taken.
VI. Summary
The core design and manufacturing logic of the SMC basin mold is to adapt to the thermosetting molding characteristics of SMC materials, achieving a balance among molding efficiency, product quality, and mold lifespan. The mold design should be based on the characteristics of SMC materials, through precise CAE mold flow analysis, scientific structural design (mold cavity, heating, exhaust, demolding systems), and strict surface treatment, to ensure that the basin products have precise dimensions, smooth surfaces, and meet the quality requirements of bathroom products; during the manufacturing process, relying on high-precision processing and professional heat treatment technologies, the mold rigidity, wear resistance, and stability can be effectively improved. During the molding stage, precise control of key parameters such as temperature, pressure, and holding time, combined with standardized quality control and daily maintenance, can effectively reduce product defects and extend the mold lifespan. At the same time, the mold selection should be combined with the actual production batch size and product positioning, and reasonable selection of mold materials, heating methods, and surface treatment processes should be made to control production costs while ensuring product quality, meeting the production needs of SMC basins of different scales and grades.
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