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Rapid prototyping is the first part that can help you test new products before mass production. It allows you to test the functionality and shape of your design, so you can be sure that it is properly designed for manufacturing.

Small batch production is the best way to test the market or adapt to inventory management before mass production. Sometimes it is necessary if the required quantity is small. We can produce more than 1,000 parts in 2 weeks, including all complex finishing.
Ruiyi is a company in China that can help you achieve prototype design or design of more than 1,000 parts through advanced manufacturing technology. Our high-quality prototyping, small batch production and rapid prototyping services are your solutions for rapid product development. Innovation, prototyping and manufacturing are the basic requirements of designers, and we are a one-stop service to meet all these needs.

Our team of engineers will work with you during the DFM phase until final shipment. In addition to 3D printing, CNC machining and plastic injection molding services, we will guide you through other outsourced processes such as aluminum extrusion and die casting. Are you ready to start a new project? Contact us today for a quote.

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1. Heating method of extruder screw barrel

The machine heater widely uses resistance heating, and uses thermocouples to realize segmented temperature control and detection. The resistance heating uses resistance to generate heat to the barrel, and then transfer the heat to the plastic in it. The method mainly includes strip heaters, cast aluminum heaters, ceramic heaters, etc., which have the advantages of small size, easy manufacturing and maintenance.

Lesun is one of the leading screw barrel suppliers in China, we have high quality screw barrels for sale at reasonable prices.

2. Temperature range of the extruder screw barrel

According to the different plasticization state of the material along the screw axis, the heating of the screw and the barrel must be carried out in sections to help improve the plasticization capacity in order to make the temperature distribution of the extruder barrel meet the process requirements. Generally, (3-5) Ds, (which is the screw diameter) is used as a heating temperature control section. The temperature control fluctuation range of heating should generally not exceed 5°C meanwhile for heat-sensitive plastics, the temperature should not be over 2°C.

3. Heating power of extruder screw barrel

When determining the heating power of the extruder screw barrel, it is also necessary to meet the requirements of productivity to ensure that the barrel has a sufficiently fast heating rate in addition to meeting the heat required for plasticization. The heating time of the machine is not more than 30 min for small machines, but generally about 1h for large and medium machines.

4. Cooling of extruder screw barrel

The design of cylinder cooling channel is adopted with a heat exchanger and a large stainless steel water tank. The cooling system shall choose softening water. Then, the cooling effect will be realized by controlling the flow of water in and out of the channel through the solenoid valve.

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The extruder should be cleaned regularly after being used for a period of time. Because a long time of using，a lot of stains will be generated inside the barrel. If these stains accumulate for a long time, it will affect the normal use of the extruder and delay the production. Therefore, regular cleaning should be carried out to ensure the normal operation of the machine.

Then how to clean the barrel of the extruder? Common extruder cleaning methods are as follows:

1. If the raw materials used for injection products are changed frequently or the plasticizing temperature range between the residual materials and the replacement is large, the barrel cleaner is used to clean the extruder. How to clean extruder barrel to save material and improve work efficiency? Generally speaking, it is more economical to use the machine barrel cleaner. Special cleaning agent is a kind of material similar to rubber, not molten in the high temperature in the barrel. The special cleaning agent in the screw thread groove is a softening gelatinous shape. When moving forward in the screw thread groove, the residual material can be taken away so that the machine barrel can be cleaned.

2. Use the refueling ejection method to clean the extruder. If the plasticizing temperature range of the newly changed raw materials is higher than that of the residual materials in the extruder barrel, the barrel and the nozzle can be heated to the plasticizing temperature of the newly changed raw materials, then new refueling is added and continuously injected into the air until there is no residual materials in the barrel.

3. If the plasticizing temperature range of the residual materials in the cylinder is higher than that of the replacement, the cylinder shall be heated to the plasticizing temperature range of the residual materials in the cylinder to remove the residual materials. After the nozzle can be added to clean, put the new material production, if the product requirements are high, the new material of the first few molds can be scrapped treatment.

Note: As an experienced screw barrel supplier, Lesun will tell you how to clean the barrel of the extruder requires some considerations. When the extruder is cleaning, please pay attention to the internal structure to avoid damage to the cylinder during dismantling and washing, which will affect the later use. Only the proper cleaning of the machine, will make the production to continue, extend the service life.

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In modern manufacturing, the advent of rapid prototyping has revolutionized product design and development. In particular, aluminum alloy rapid prototyping, with its unique advantages and flexibility, has become an important and indispensable tool for product designers in the design verification and product development process. This article will delve into how aluminum alloy rapid prototyping can bring multiple benefits to product designers.

Basic Principles of Aluminum Rapid Prototyping

Aluminum rapid prototyping is a manufacturing process that quickly turns aluminum alloy materials into complex prototypes or finished products through technologies such as CNC machining (CNC) or 3D printing. The core advantage of this technology is that it eliminates the need to rely on traditional molds and can generate high-precision physical models directly from digital design files. This not only saves time and cost in mold making, but also allows designers more freedom to explore a variety of complex and innovative designs.

Shorten Product Development Cycle

In a competitive market, the speed of product development often determines the success or failure of an organization. Aluminum rapid prototyping can significantly shorten product development cycles, allowing designers to validate and optimize their designs in a short period of time. In traditional manufacturing processes, tooling is often time-consuming, and if there are problems with the design, multiple adjustments are required, which is not only time-consuming but also costly.

In contrast, aluminum additive manufacturing can directly generate functional prototypes, allowing designers to quickly make multiple iterations to test the feasibility and functionality of their designs. This flexibility allows products to be brought to market faster to meet customer and market needs.

Improved Accuracy in Design Verification

Design verification is a critical step in the product development process, and aluminum rapid prototyping plays a particularly prominent role in this process. Aluminum prototypes are more representative than prototypes made from other materials because their mechanical properties are close to those of the final product. This allows designers to accurately test prototypes to more accurately assess the performance of a design.

For example, in the automotive or aerospace sectors, designers need to ensure that parts will function properly under high strength and stress. With prototypes made from aluminum additive manufacturing, designers can test their products in real-world environments and obtain more reliable performance data. This not only reduces the risk of design errors, but also improves the final quality of the product.

Promoting Innovation and Flexibility

Aluminum additive manufacturing offers designers great design freedom, allowing them to explore more innovative design possibilities. While traditional manufacturing processes are often limited by tools and materials, aluminum alloy additive manufacturing allows for complex geometries and unique designs.

The technology is particularly well suited for prototyping and small-volume production, allowing designers to quickly try out different design options and choose the optimal one. This flexibility not only inspires more creativity, but also makes products more unique and competitive.

Reduced Production Costs

Although the cost of aluminum alloy material is high, aluminum alloy rapid prototyping technology has a significant advantage in reducing the overall production cost. Traditional manufacturing processes are costly in terms of tooling, especially when it comes to small batch production. However, aluminum alloy rapid prototyping can process parts directly through CNC or 3D printing without the need for tooling, thus saving significant upfront investment.

In addition, the high precision and consistency of aluminum alloy rapid prototyping reduces material waste and rejects. This not only helps companies control their budgets, but also enables them to devote more resources to product innovation and optimization.

Improving Product Performance and Quality

Aluminum alloys are used in a wide range of industries for their excellent performance. Through additive manufacturing, designers are able to create prototypes that are strong, corrosion-resistant and have excellent thermal conductivity. These properties are critical to the performance and quality of the final product.

For example, in consumer electronics, aluminum alloy prototypes can mimic the thermal characteristics of a product, helping designers optimize the internal structure and improve the product’s thermal performance. In applications that require high strength and light weight, such as automotive and aerospace, aluminum additive manufacturing can provide strong support to ensure that products meet performance requirements while weighing less.

Supporting complex design and customization needs

As market demands become more diverse and individualized, product designers need to be able to respond quickly to the customization needs of different customers. Aluminum additive manufacturing has the advantage of supporting the realization of complex designs, whether it is complex geometries or multi-functional integrated components.

With Aluminum Additive Manufacturing, designers can offer customized solutions and deliver high-quality products in a short period of time. This not only improves customer satisfaction, but also enhances the competitiveness of the product in the market.

Environmentally friendly and sustainable

In modern manufacturing, environmental friendliness and sustainability have become important considerations. Aluminum additive manufacturing excels in this regard. Aluminum is a recyclable material that is produced with less material waste and lower energy consumption. This not only reduces the impact on the environment, but is also in line with the concept of sustainable development.

For product designers, choosing aluminum alloy rapid prototyping technology not only improves the performance and quality of their products, but also wins over more consumers through environmentally friendly manufacturing. This environmentally friendly manufacturing method has a high brand value in today’s market.

Reduce waste of resources

In addition to rapid production, another advantage of rapid prototyping is reduced waste. Due to the generated structure of the object, no large amount of waste is generated like other processes (such as cutting, grinding, milling or turning). Therefore, using rapid prototyping can also help you save resources.

Conclusion

Aluminum rapid prototyping provides product designers with comprehensive support from design verification to product manufacturing. Whether it is to shorten the development cycle, improve design accuracy, or promote innovation and reduce costs, aluminum alloy rapid prototyping has demonstrated its strong advantages and wide application prospects.

As technology continues to advance, aluminum alloy rapid prototyping will bring more possibilities to product designers in the future, enabling them to create more innovative, powerful products that meet market demands. The continuous development of this technology will further promote innovation and progress in various industries, bringing consumers a higher quality product experience.

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