Transfer molding, a widely employed technique in electronics manufacturing, plays a crucial role in potting electronic assemblies. While some may be unfamiliar with its name, it is not only prevalent but also a step beyond compression molding in terms of complexity. Compared to compression molding, transfer molding enables the production of more intricate geometries, although it falls short of the complexity achieved through injection molding. With its focus on low to medium volume production, transfer molding predominantly utilizes thermosets, rubbers, and compound materials with specialized fillers to enhance their properties. Notably, ADDMAN Group, via or HARBEC division, excels in handling such specialty materials.
Why is Transfer Molding Beneficial?
The significance of transfer molding lies in its ability to mold thermosetting materials into relatively complex geometries and encase metal inserts or electronic components under relatively low pressures. This is particularly applicable to components like spark plugs, cable connectors, and high-temperature car parts with metal connector pins. Additionally, the cost of equipment required for transfer molding is comparatively low, making it an ideal fit for low-volume, highly precise, custom electronic assemblies that integrate a combination of molded, machined, and electrical components.
In the process depicted in the accompanying image, material preheating occurs in the primary chamber, followed by the use of a plunger to force the material through a channel leading to the cavity of the molded part. Unlike compression molding, transfer molding can exert higher pressures, enabling the production of parts with tighter tolerances and more intricate geometries. Another image illustrates the fundamental functions of solenoids.
Transfer Molding in the Aerospace Industry
Within the aerospace industry, HARBEC has adopted transfer molding technology to manufacture solenoids. Solenoids are devices consisting of a coil of wire that generates a magnetic field upon the application of electrical current, enabling precise activation of pistons, gears, latches, and more. Transfer molding proves advantageous in this context as it allows electronic components or machined inserts to be enclosed and cured within a cavity, effectively filling in voids and unused space in the assembly, a process commonly known as “potting.” For aerospace customers, the key concern is ensuring that the electronic assembly can withstand vibrations and impacts while maintaining optimal functionality.
Your Trusted Transfer Molding Service Provider
We offers comprehensive transfer molding services, managing the entire process from start to finish. This includes machining a metal outer housing, applying post-process plating, injection molding the spool, winding the spool with copper wire to form the solenoid, assembling and installing a circuit board, crimping pin connectors, integrating the spool into the machined housing, and encapsulating the entire assembly through potting. The completed part undergoes inspection according to IPC Space standards and is subject to extensive electrical testing on custom-built automated test station to ensure optimal performance.
With ADDMAN Group, you have access to a convenient one-stop shop solution. Contact us today to embark on your project.
