2. DFM REPORT Project Name: Climate Gen 2 Part Name: IR_Window
Prepared by:
Kui
Approved by:
Chau Yu
Issue Date:
25 Feb., 2017
Revision: R3

3. Parts and mould info.

4. Dimensions of geometry

5. SPLIT PARTING LINE EM: 25/01/2017
Fix side
EM: 25/01/2017
We need invest gate if sink marks will occur around the tower areas
Let see mold flow result.
Moving side
Fix side
Radius Comment ( ):
OK.
Moving sie

6. Dimensions of geometry
Radius Comment ( ):
Please refer to updated 3D sent on
Radius Comment ( ):
OK, please provide the recommended geometry and 3D can be updated accordingly.
If not reduce the rib, the weld line get at visible surface. See page 14 to 18.
EM: 25/01/2017
Suggest cut some plastic avoid weld line at visible surfaces.
And it is better for weld line issue.
The mold flow details showing at page 20 to 24.

7. Draft Checked Ok

8. Gate point suggestion
Side gate

9. Ejector mark location Ejector Dia 1.5 x 6( 3x) Ejector Dia 1.5(2x)
Radius Comment ( ):
Please refer to updated 3D sent on
Ejector Dia 1.5 x 6( 3x)
Ejector Dia 1.5(2x)
Ejector Sleeve
O.D=3.8 I.D=2.5 (2x)
Insert pin
Radius Comment ( ):
OK.
Radius Comment ( ):
This pin and ribs will not be made at first. Will decide to make it or not after review off tool parts. (corresponding to steel safe feature in Housing.)
Excel comment –
Because both side already have two ejector pins, so we suggest keep the ejector on middle
Radius Comment ( ):
Consider the strength of part, suggest to change the middle ejector to 2 ejectors aside (in purple). Agree?
Excel comment –
Ok, we will not make this pin and rib first

10. SURFACE/TEXTURE/FINISHING REQUIREMENTS
Green color area B2 polishing
Radius Comment ( ):
OK. A2
Fix Half Finishing:
Moving Half Finishing: A2

11. We could add Resin name, If in need
PARTS MARKING
Suggest marking area
>PC<
We could add Resin name, If in need
Radius Comment ( ):
Change the material identification code to here due to re-arrangement of ejectors.
Radius Comment ( ):
OK.
Excel comment –
Ok, we will make the material identification on middle ejector.

12. PRELIMINARY MOULD LAYOUT ESTIMATION
Mould base size: W280(230) x L250 x H271mm
Mold TOP
Radius Comment ( ):
Please show also the cooling system arrangement.
Excel comment –
Please see next page

13. PRELIMINARY COOLING LAYOUT
Move side
Fix side

14. MOLDFLOW ANALYZE： Material：PC Makolon 2805 Radius Comment (20170208):
This part require IR transparent.
Please use Bayer Makrolon 2805; color #: , Black
Please refer to information attached.
Material：PC Makolon 2805

15. MOLDFLOW ANALYZE：Fill time
Radius Comment ( ):
OK. This area is hard to be visible.
Suggest to adjust molding parameters to optimize the quality.
Weld line at visible surface

16. MOLDFLOW ANALYZE：Temperature at flow front
Radius Comment ( ):
OK. Let’s keep current geometry and see the actual off tool parts.
May require adjusting molding parameters to optimize the quality.
Temperature at flow front between to degree,
Temperature different large than 10 degree, a little bit big different.
Remark：Melt temperature-300 degree.

17. MOLDFLOW ANALYZE：Air traps

18. MOLDFLOW ANALYZE：Sink marks estimate
Smaller sink area 0.06mm
Radius Comment ( ):
Will the sink mark be visible?
Can it be eliminated by adjustment molding parameter or any other suggestion?

19. MOLDFLOW ANALYZE ： Deflection all effects
Radius Comment ( ):
OK. Let’s review the actual off tool parts.
May not be significant from device perspective as IR Window is always lower than Housing.
Some deflect
Reduced the sink mark factor(0.6%), The highest value of deflection is 0.28mm 。