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Manufacturing Vacuum Cast Plastic Parts Robotics Nylon PA66 PEEK Joints Housing Units
Product Description:
In the robotics industry, components must be lightweight, durable, and capable of withstanding repetitive movement and heavy loads. Vacuum casting is an increasingly popular method for producing plastic parts used in robotics, as it allows for the creation of precise and high-performance components that meet the demanding requirements of this industry. Materials like Nylon PA66 and PEEK (Polyetheretherketone) are commonly used for robotics parts due to their exceptional mechanical properties and high resistance to wear and heat.
Nylon PA66 is known for its excellent strength, stiffness, and wear resistance, making it ideal for components like robotic joints, gears, and housings that experience frequent friction and mechanical stress. It is also lightweight and can be easily molded into complex shapes, making it suitable for creating intricate parts that fit into tight spaces. PEEK, on the other hand, is a high-performance material that excels in extreme conditions. It is resistant to high temperatures, chemicals, and wear, which makes it perfect for critical robotic components such as joints, connectors, and housing units that must operate reliably in harsh environments.
Vacuum casting is a highly effective method for producing these robotics parts. The process begins with a master model, which could be a 3D-printed prototype or an existing part. This master is used to create a silicone mold, which captures all the fine details of the design. Liquid resin, such as Nylon PA66 or PEEK, is injected into the mold under vacuum pressure, ensuring that the resin fills every part of the mold and results in parts with smooth surfaces and precise dimensions.
The use of vacuum casting for robotics allows manufacturers to quickly produce prototypes and low-volume production parts. This is particularly useful for developing new robotic systems or testing out different design iterations. By using Nylon PA66 and PEEK, manufacturers can produce parts that have the strength, durability, and heat resistance required for demanding robotic applications. Whether it’s for building robotic arms, autonomous vehicles, or drones, vacuum casting offers a versatile and efficient solution for producing high-quality robotic components.
Applications of vacuum casting
Vacuum casting is one of the most cost-effective ways to produce high quality, low volume plastic parts which can be similar to injection moulding parts
The parts are especially suitable for form, fit and function tests during the embodiment design stages, where they can be used for marketing, field user testing and product design verification purposes
There are many Urethane casting resins commercially available that can be used to create parts to satisfy a wide range of design requirements such as temperature requirements, different surface textures, hardness, etc.
Materials are also available to create parts that are fully opaque, translucent or completely transparent
Sometimes high-quality wax masters can be made using vacuum casting for investment casting to increase the finer details of intricate features
| Time frame | Within 24 hr – 5 working days for up to 30-50 parts |
| Material choice | Wide variety of materials available |
| Accuracy | ±0.3% (with a lower limit of ± 0.3 mm on dimensions smaller than 100 mm) |
| Minimum wall thickness | To ensure that the mould is filled properly, a wall thickness of at least 0.75 mm is necessary. But best results are achieved with a recommended wall thickness of 1.5 mm |
| Maximum part dimensions | The size of the mould is limited by the dimensions of the vacuum chamber |
| Typical quantities | Up to 50 parts per mould |
| Surface structure | Gloss to Matt surface finish can be obtained |
Polyurethane (PU), the full name of polyurethane, is a polymer material formed by polyol and polyisocyanate through polycondensation reaction with excellent mechanical properties
[1], which is extremely plastic. Its synthesis can be traced back to 1937, when Professor Byaer first synthesised straight-chain linear polyurethane resins using 1,6-hexanediisocyanate and 1,4-butanediol as raw materials
[2]. Several major classifications of polyurethanes include polyether-type, polyester-type, polyimide-type, and polyurea-type, etc. They can be made into materials such as polyurethane plastics (mainly foams), polyurethane fibres (known as spandex in China), polyurethane rubbers and elastomers
[3].After nearly eighty years of technological development, this material has a wide range of applications involving products such as coatings, adhesives, fabric finishes, leather modifiers, polyurethane soft/rigid foam, elastomers, etc., which are used in the fields of textiles, construction, aviation, shipping, transportation, medicine, electronics, and so on.
Flexible polyurethane mainly has a linear structure with thermoplasticity, which has better stability, chemical resistance, resilience and mechanical properties than PVC foams, with less compression variability. Heat insulation, sound insulation, shock resistance, anti-virus performance is good. Therefore, it is used as packaging, sound insulation and filtration materials. Rigid polyurethane plastic is lightweight, sound insulation, superior thermal insulation performance, chemical resistance, good electrical properties, easy processing, low water absorption. It is mainly used in construction, automotive, aviation industry, thermal insulation structure materials. Polyurethane elastomer performance between plastic and rubber, oil resistance, abrasion resistance, low temperature resistance, aging resistance, high hardness, elasticity. It is mainly used in the shoe industry and the medical industry. Polyurethane can also make adhesives, coatings, synthetic leather, etc.
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