1, What is the replication process?
The basic process of replication is to first create a master mold (i.e. the original sample) through 3D printing or CNC machining, then suspend the master mold in the mold box, inject liquid silicone, and after the silicone solidifies, cut open and remove the master mold to obtain the silicone mold. Finally, in a vacuum environment, liquid polyurethane resin (PU) is injected into the silicone mold and cured to obtain a replica.
Pay attention: The entire cycle usually takes only 3-5 days, which is very fast and flexible.
2, The core characteristics of the replication process
Characteristic Description
Low cost, no need for steel molds, silicone molds cost only a few tens of times less than injection molds, especially suitable for the production of 20-100 pieces.
The high fidelity dimensional accuracy can reach ± 0.1mm, and can replicate fine patterns and complex geometric features of over 0.1mm.
The materials are diverse and can mimic the mechanical properties and surface effects of materials such as ABS, PC, PP, PMMA, rubber, etc. They can also be added with colors or special fillers.
The surface effect is good, and the product directly reproduced from the mold has a surface close to the injection molded part, which can be used for secondary processing such as painting, screen printing, electroplating, etc.
The production cycle is short, usually 3-7 days from the master mold to the finished product, much faster than injection molding.
Limitations: Silicone molds have a short lifespan and can generally only produce 20-30 pieces (with fewer complex parts), making them unsuitable for large-scale production; High requirements are placed on the surface quality of the master mold, and defects in the master mold will be directly replicated on the replica.
3, Typical application scenarios
1. New product development and functional verification
Before the product is finalized, multiple sets of prototypes are required for assembly testing, drop testing, temperature resistance testing, etc. Remake can provide 10-20 sets of functional samples at a lower cost, which is closer to the mechanical properties of real injection molded parts than 3D printing.
2. Small batch customized products
For example, medical equipment shells, intelligent hardware shells, robot parts, aerospace lightweight components, etc., the demand is often between 50-200 sets, and the cost of injection molds is too high. Remaking is the most cost-effective choice.
3. Exhibition samples and market trials
Before the official mold opening, a small number of exquisite samples need to be made for exhibition display, customer trial, or crowdfunding promotion. Remake can be delivered quickly, and the appearance and texture are no different from mass-produced parts.
4. Silicone soft parts
Remake is also suitable for making soft rubber parts, such as sealing rings, cushioning pads, medical silicone tubes, etc., and can achieve Shore A softness of 20~90 by adjusting the hardness of polyurethane.
4, Frequently Asked Questions (FAQ)
Q1: Can replica molds produce transparent parts?
Okay. By using transparent polyurethane resin and polishing it, high transparency parts can be obtained, with transparency close to acrylic.
Q2: How much strength can a replica achieve compared to an injection molded part?
High quality polyurethane resin (such as ABS resin) has tensile strength and impact strength that can reach 80% -95% of injection molded ABS, fully meeting functional testing requirements.
Q3: Can you replicate based on the sample?
Okay. Customers only need to provide one sample (or 3D drawing), and we can scan or directly remake the silicone mold. But the surface of the mother sample must be smooth and defect free.
Q4: What is the minimum order quantity?
There is no minimum order quantity, one piece can also be made. However, considering the cost of mold production, it is generally recommended to make at least 5-10 pieces to dilute the cost.
Q5: Can dual color or multi hardness parts be made with replica molds?
The standard replica is made of a single material. Two color injection molding requires special processes and cannot be replicated. But it can be bonded later or injected again.
Q6: Can silicone molds be reused?
Silicone molds can produce 20-30 pieces under normal use. If the mold is damaged or deformed during the production process, it needs to be remade.
Shenzhen StrongD Model has over ten years of experience in mold replication and can provide you with complete services from master mold production, silicone mold to small batch production. Whether you are in the early stages of product development or small batch customization, please feel free to contact us for a quick quote.
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