Cylindrical battery foam holder, rigid PU foam molding
FEATURES
Hard Power Infrastructure — The Foundation of Customer Trust
Precision Machining Equipment
Ansix Tech's equipment portfolio directly translates to superior part quality and reduced finishing costs. The company operates:
5-Axis High-Speed Machining Centers: Achieving machining accuracy of 0.002mm on complex curved surfaces. For cylindrical battery foam holders, this translates directly to parting lines that are smooth and flash-free, eliminating costly manual deflashing operations. Customer Value: No secondary trimming required; reduced labor costs; consistent cosmetic appearance.
Slow-Wire EDM (Electrical Discharge Machining): Capable of machining features as fine as 0.03mm in width for micro-pores and narrow slots. This is critical for thin-wall sections where deformation must be prevented. Customer Value: Precision thin-wall molding without distortion; consistent wall thickness across millions of cycles.
High-Precision Grinding and Polishing Equipment: Achieving surface roughness values as low as Ra 0.05μm for cavity and core surfaces. Customer Value: Optical clarity for transparent applications; zero adhesion defects; superior cosmetic finishes.
Multi-Stage Double-Taper Positioning Technology: For multi-cavity molds, maintaining perfect concentricity between core and cavity with eccentricity within 0.05mm. Customer Value: Eliminates dimensional "drift" that plagues lesser molds after extended production runs.
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Mold Description
Product Materials:
PU FOAM
Soft rubber: PU
Mold Material:
S136ESR
Number of Cavities:
1
Glue Feeding Method:
Hot runner
Cooling Method:
Water cooling
Molding Cycle
42.5s
- The mold manufacturing process and product material selection
Injection Molding Machine Fleet
Ansix Tech operates 260 injection molding machines with clamping forces ranging from 30 tons to 4,000 tons, covering product sizes from micro-scale components under 1 gram to large automotive parts exceeding several kilograms.
Machine Brands: The fleet includes Japan's Fanuc, Sumitomo, Toshiba, Nissei, Engel, Germany's Arburg (primarily for liquid silicone injection molding), and China's Haitian and Victor Taichung Machinery.
All-Servo Electric Drives: All machines are equipped with all-servo electric drives, delivering stable process repeatability of ±0.1% variation from shot to shot. Customer Value: From the first shot to the millionth, every unit is identical — predictable quality, zero unexpected variation.
Quality Inspection Equipment
CMM (Coordinate Measuring Machines) and Optical Imaging Systems: Every mold undergoes a full dimensional report before leaving the shop, with Critical-to-Quality dimensions (CPK) maintained at ≥ 1.33. Customer Value: A CPK of 1.33 means the manufacturing process is capable of producing 99.9937% of features within specification — virtually eliminating the risk of receiving non-conforming tooling.
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Cylindrical Battery Foam Holder and Rigid PU Foam Molding — Product Introduction
Product Overview
Cylindrical battery foam holders are precision-molded components designed to house and protect sensitive lithium-ion battery cells. These components must provide:
Electrical insulation to prevent short circuits
Mechanical protection against vibration and impact
Thermal management to dissipate heat
Dimensional accuracy for proper cell alignment
Flame retardancy (UL94 V-0 rated) for safety compliance
Rigid PU (polyurethane) foam molding produces structural foam components with a solid skin layer over a microcellular foam core. This technology enables the production of high-quality, durable parts with improved strength-to-weight ratios.
Ansix's rigid PU foam meets the following technical standards (fully satisfying customer expectations):
Rigid PU foam molding foam application
General requirements
Physical/Mechanical Properties spec
Specification Unit Value
Temperature range ºC -50ºC to 150ºC
Closed cell content % >99
Foam density after mixed (free raise) g/L 200-300
Hardness shore-A (DIN EN ISO 868) - 70A-90A
Tensile strength (ISO 1798) MPa 3
Break elongation (ISO 1798) % 15
Tensile modulus (ISO 1798) MPa 10
Flexural modulus (ISO 178) MPa 10
Flexural strength (ISO 178) MPa 1-1.5
Pressure strength (ISO 604) MPa 1-1.5
Glass transition temperature (DSC) (ISO 11357-2) ºC 100+
Thermal-linear-coefficient-(TMA)-at -40°C and
+100°C (ISO 11359-2)
/K 75 10-6 - 250 10-6
Fire resistance - UL-94 V-0
Insulation resistance @ 500 VDC,
60 s, 23 °C/50 % RH Ω ≥1×10¹¹
Thermal conductivity (ASTM D 5930) mW/mK 70
Minimum wall part thickness mm 1.5
Internal Voids % < 1
Chemical compatible with PAO/synthetic
Hydrocarbon oils - Yes
Water absorption, % mass increase (24h storage
under10cm water) % < 0.6
Material Selection
For Cylindrical Battery Foam Holders:
Ansix Tech employs a rigorous, customer-value-oriented material selection framework. Common materials include:
Material Key Properties Application
PC/ABS High impact resistance, good dimensional stability Battery housings, structural supports
PC Excellent transparency, high heat deflection temperature Clear battery covers, optical applications
PP-GF30/GF40 Superior stiffness, creep resistance, thermal stability (HDT >120°C) Structural battery frames, high-load components
PPS+40%GF Exceptional chemical resistance, high-temperature stability (550-600°C hot hardness) High-temperature battery applications
PEEK Ultra-high temperature resistance, superior mechanical properties Premium battery components, aerospace-grade applications
PA6+GF30 Good mechanical strength, cost-effective Mid-range battery holders
PBT Excellent electrical insulation, dimensional stability Electrical connector housings
For Rigid PU Foam:
Rigid PU foam systems are specially blended to produce tough, rigid, and structural moldings to high specification. Key material characteristics include:
Flame retardancy: Meeting UL94 HF-1, FMVSS 302, and EN 13501-1 standards
Energy absorption: Reversibly deformable under low forces; greater loads dissipated through cell deformation and heat conversion
Lightweight construction: Improved strength-to-weight ratios reduce material costs while maintaining integrity
Design flexibility: Foaming enables complex and large geometries adapted to available space
Part Three: Mold Manufacturing — Core Competitiveness
Mold Steel Selection
Ansix Tech maintains strategic inventory of premium tool steels specific to each application, ensuring material properties match exact service conditions:
Steel Grade Hardness (HRC) Key Properties Best Fit Application
S136 / S136H Pre-hard: 35-35 / Quench: 48-54 Superior corrosion resistance, ultra-high mirror polishability (Ra <0.05μm), excellent wear resistance Transparent PC/ABS parts, optical-grade surfaces, corrosive plastic materials
2344 / 8407 / H13 48-52 (Quench & temper) High hot hardness at 550-600°C, excellent toughness, superior thermal fatigue resistance High-temperature engineering plastics (PPS+40%GF, PEEK), high-thermal-load injection molds
NAK80 37-43 (Pre-hard) Super mirror polish (up to #15000), excellent EDM machinability High-gloss surfaces, cosmetic-grade appearances, fine-textured finishes
SKD11 / DC53 58-62 High wear resistance, high compression strength Wear inserts, sliders, shear edges subjected to abrasive filled materials
2343 48-52 Impact resistance superior to H13, good thermal conductivity Complex geometries with extreme mechanical shock loads
M340 / 4Cr13 / 9Cr18 48-53 Stainless martensitic, excellent corrosion resistance FDA-grade applications, acidic plastic compounds, humid environments
P20 28-32 (Pre-hard) Good machinability, cost-effective Mold bases, support plates, non-critical core/cavity applications
Heat Treatment Documentation: Each mold undergoes strict heat treatment protocols with documented time-temperature curves. For S136, the process follows a precise quench at 1000-1050°C, oil-cooled to 50-100°C, then tempered at 200+°C to achieve 48-54HRC while preventing cracking.
Customer Value: Full material traceability; documented heat treatment curves; guaranteed mold life — with premium steels, Ansix Tech guarantees 1,000,000 production cycles under normal processing conditions before major refurbishment is required.
Mold Design and Engineering
DFM (Design for Manufacturability) Reports: Ansix Tech provides comprehensive mold feasibility analysis reports before signing contracts, including:
Draft angle recommendations
Wall thickness optimization
Gate location analysis
Ejector pin mark location allowances
Weld line and gas trap prediction through Moldex3D Flow simulation
Customer Value: Problems are identified and solved before mold manufacturing begins — avoiding costly redesigns after tooling is already cut.
Hot Runner Systems: Reducing material waste and improving cycle efficiency.
Cooling System Design: Water cooling with optimized channel布局 ensures uniform temperature distribution. Customer Value: Reduced cycle times; consistent part quality; minimized warpage.
Mold Manufacturing Process Flow
CAD Design & DFM Analysis — Engineering review with Moldex3D simulation
Steel Selection & Procurement — Premium tool steels with full certification
Rough Machining — 5-axis high-speed CNC for initial cavity/core roughing
Heat Treatment — Precise quenching and tempering with documented curves
Precision Machining — 5-axis finishing to 0.002mm accuracy
EDM (Wire & Sinker) — 0.03mm precision for fine features and narrow slots
Grinding & Polishing — Surface finish to Ra 0.05μm
Assembly — Multi-stage double-taper positioning for perfect alignment
Testing & Validation — Full dimensional inspection with CPK ≥1.33
Trial Molding — T0 to T3 samples with improvement reports
Part Four: Injection Molding Process Control — Eliminating Quality Anxiety
Process Standardization
MES-Integrated Process Control: All machines are networked with molding parameters (temperature, pressure, speed, time) locked in the MES system — only authorized engineers can make adjustments. First-article and last-article inspections are performed for every batch.
Customer Value: No unauthorized process changes; consistent quality across every shift; full traceability.
Dimensional Stability Control
Temperature Zone Control: Mold temperature is controlled by zone-specific units, maintaining core and cavity temperature differentials within 2°C to minimize warpage and deformation.
Real-Time Monitoring: Injection molding machines are equipped with ultrasonic wall thickness sensors, providing real-time feedback on wall thickness fluctuations and automatically compensating holding pressure.
Closed-Loop Control: In-mold temperature and pressure sensors enable closed-loop control for critical dimensions.
Customer Value: For battery holder products, critical hole spacing fluctuations are maintained within ≤0.02mm across three consecutive production batches — predictable, repeatable dimensions.
Appearance Quality Standards
Requirement Capability
Transparent parts No bubbles, no flow marks
Plated parts No gas marks
High-gloss parts Surface roughness Ra ≤0.2μm
Printed/painted parts Print registration accuracy ±0.1mm with pre-compensated deformation
Special Material Processing Capabilities
Ansix Tech has extensive experience with a wide range of engineering plastics:
PC/ABS
PC
PPS+40%GF
PEEK
PTFE/PFA
PA6+GF30
PBT
PEI/PPS/LCP
Liquid Silicone Rubber (LSR)
Flame-retardant grades meeting UL94 V-0 standards
UV-resistant grades tested to 3,000 hours without discoloration
Part Five: Full-Process Service — Reducing Customer Management Costs
Early Intervention (DFM Reports)
Before contract signing, Ansix Tech provides comprehensive mold feasibility analysis reports:
Draft angle recommendations
Wall thickness optimization
Gate location analysis
Ejector pin mark location allowances
Customer Value: Problems are identified before mold manufacturing begins — avoiding costly redesigns after tooling is already committed.
Trial Molding and Samples
T0 to T3 Sample Provision: Ansix Tech provides samples at each trial stage, accompanied by improvement reports. Quick-change inserts allow verification of different设计方案 without re-manufacturing the entire mold.
Customer Value: Rapid design iteration; reduced development time; lower risk.
Small-Batch Verification
Before full-scale production, Ansix Tech provides 100-500 shot trial runs, with yield statistics and CPK analysis to confirm process stability before mass production.
Customer Value: Production readiness verified before large capital commitment; no surprises during scale-up.
Maintenance and Spare Parts
Spare Parts Package: Wear parts (ejector pins, core inserts) are delivered with the mold.
Preventive Maintenance: Mold maintenance provided every 200,000 cycles.
Lifetime Repair: Repairs provided at cost price for the lifetime of the mold.
Customer Value: Minimized production downtime; predictable maintenance costs; extended mold life.
Part Six: Cost Control and Delivery Assurance
Cost Reduction Strategies
Material Optimization: Ansix Tech's material selection strategy is performance- and cost-optimization-driven. By selecting the optimal material grade for each application, material costs are reduced without compromising performance.
Process Optimization: Through advanced simulation (Moldex3D) and process optimization, cycle times are minimized. For example, a 96-cavity syringe mold achieves a 12.5-second molding cycle.
Efficiency Improvement: The company's vertical integration approach — covering prototyping, mold manufacturing, injection molding, and final assembly verification — provides resilience against supply chain disruptions.
Automation: With an automated machining ratio of 70% and an average of just two mold trials before production readiness, Ansix Tech significantly reduces development costs and time-to-market.
Customer Value: Lower unit costs; reduced time-to-market; predictable pricing.
Delivery Assurance
Production Capacity: With 260 injection molding machines and 200,000 m² of production space, Ansix Tech has the installed capacity to scale from prototyping to millions of units per month without re-tooling or capacity bottlenecks.
Global Manufacturing Footprint: Four production bases in China and Vietnam provide geographic diversification and risk mitigation.
Lead Time Standards:
Mold Complexity Standard Lead Time Rush Service
Simple molds 10 days Available
Medium-complexity 25-45 days Compressed to 20 days
Complex molds 45-60 days Expedited
Rush Service Guarantee: Rush service is available while preserving all validation steps — no shortcuts on quality.
Customer Value: On-time delivery; production schedule protection; reduced inventory carrying costs.
Part Seven: Quality Assurance and After-Sales Service
Quality Management System
Ansix Tech maintains a complete quality control system with certifications:
ISO9001 — Quality management
IATF16949 — Automotive industry quality
ISO13485 — Medical device quality
ISO14001 — Environmental management
BSCI — Social compliance
ISO Class 8 Cleanroom and GMP compliance, meeting US medical grade FDA510K standards.
Quality Verification Process
Raw Material Inspection — Material certification and incoming inspection
In-Process Inspection — Continuous monitoring during machining
Final Dimensional Inspection — Full dimensional report with CPK ≥1.33
2000-Cycle Aging Test — Wear report provided before delivery
Trial Molding Validation — T0 to T3 samples with improvement reports
Customer Value: Zero non-conforming tooling risk; production schedule protection from day one.
After-Sales Service
24-hour response to customer inquiries
Lifetime technical support
On-site troubleshooting when required
Spare parts availability — wear parts delivered with mold
Preventive maintenance scheduling every 200,000 cycles
Lifetime repair service at cost price
Part Eight: Differentiated Advantages — Solving Common Industry Pain Points
Customer Pain Point Ansix Tech's Solution Delivered Value
Frequent mold repairs disrupting orders 2000-cycle aging test before delivery; 3-year mold structure warranty (excluding normal wear parts) Predictable production; reduced downtime
Excessive flash requiring costly secondary finishing 0.005mm parting line fit accuracy; self-locking clamp force compensation; flash controlled to ≤0.03mm Eliminates manual deflashing; reduced labor costs
Inconsistent dimensions batch-to-batch Ultrasonic wall thickness sensors; closed-loop pressure compensation; in-mold temperature/pressure sensors Stable dimensions; reduced scrap
Long repair cycles In-house electrode machining and EDM workshops; repairs completed in-house; 24-hour restoration for standard repairs Minimized downtime; faster recovery
High total cost of ownership Premium steel selection; optimized cooling design; predictive maintenance program Extended mold life; lower per-part cost
Conclusion: The Ansix Tech Value Proposition
For customers seeking cylindrical battery foam holder and rigid PU foam molding solutions, Ansix Tech delivers:
Customer Need How Ansix Tech Delivers
Design & Development DFM reports with Moldex3D simulation; design optimization before tooling
Product Validation T0-T3 samples with improvement reports; 100-500 shot small-batch verification
Mass Production 260 injection molding machines (30-4,000 tons); 200,000 m² production space
Quality Assurance ISO9001/IATF16949/ISO13485; CMM inspection; CPK ≥1.33; 2000-cycle aging test
Cost Control Material optimization; process efficiency; 70% automation; vertical integration
Delivery 10-45 day lead times; rush service available; global manufacturing footprint
After-Sales 24-hour response; spare parts package; lifetime repair at cost
With over 28 years of experience, 30,000+ molds delivered, and precision capabilities reaching 0.002mm, Ansix Tech has the expertise, infrastructure, and commitment to deliver reliable, high-quality cylindrical battery foam holders and rigid PU foam molding solutions that meet the most demanding customer requirements.
"For us, a mold is not just a block of steel — it is a money-printing machine. We design molds with injection molding robustness, exhaust paths, and temperature balance pre-planned, so when it reaches your production line, it runs with zero debugging, minimal flash, and maximum longevity."
Ansix Tech Co Ltd
If you have any plans related to Cylindrical battery foam holder, rigid PU foam molding , you can contact us at any time. We will turn your ideas into reality, let you realize your dreams, and obtain large orders from the market. Our contact information is info@ansixtech.com. Or contact our CTO, mail: stephen@ansixtech.com
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