Parts that you may have considered impossible to mold in the past, may be possible with x-melt.

x-melt Battery Cover Mold

cannot be molded conventionally, or cannot be molded efficiently and consistently with conventional processing techniques. One key thing to keep in mind with thinking about this process is this; when using conventional high speed injection, the first thing that happens is the plastic is compressed as the screw moves forward. The plastic eventually starts to expand, but when the shot size is small and when dealing with thin wall, high speed injection,  most of the part filling actually takes place with the material expansion after the screw has already stopped moving.

The fact that te part is actually not really filling with the screw movement translates to this: it is the plastic expansion that is filling the part, not the screw movement. The screw is only adding inconsistent variables into the process; check ring, screw or plunger position, and viscosity variations that are not taken into consideration in the normal process.

With x-melt, the plastic is compressed to a set amount first, then a valve opens and there is effectively INSTANT accelleration at extremely high flow front speeds (in the range of 2600 mm/sec) filling the cavity. The screw is absolutely stationary. The shear is over in such a short period of time (because the plastic expands so fast) that it has no negative effects on the material. Extremely thin walls are filled easily, very fine details are filled easily, and this process is extremely repeatable because Continue reading X-Melt Process opens new doors