Electric motorcycle battery bracket, oil cell holder and cell holder PU foam molding

FEATURES

• Product and Raw Material Introduction

  Electric Motorcycle Battery Bracket

  The Electric Motorcycle Battery Bracket is a structural component designed to securely mount and position the battery pack within an electric motorcycle's frame. This bracket serves as the primary interface between the battery system and the vehicle chassis, ensuring that the battery remains stable under all operating conditions including vibration, impact, and thermal expansion. Battery brackets are typically manufactured from high-strength engineering plastics or composite materials that provide electrical insulation, vibration resistance, and corrosion protection. The bracket must accommodate various battery form factors while maintaining precise dimensional tolerances to ensure proper alignment with electrical connections and thermal management systems.

   

  Oil Cell Holder

  The Oil Cell Holder (also referred to as oil cell bracket or reservoir holder) is a specialized component used in hybrid or oil-cooled electric motorcycle systems. In certain electric motorcycle architectures, oil is utilized as a cooling medium for battery cells or power electronics. The oil cell holder provides a secure mounting structure for oil reservoirs, oil filters, or oil cooling cells within the vehicle. These holders must exhibit excellent chemical resistance to oils and coolants, thermal stability across operating temperature ranges, and mechanical strength to withstand pressure fluctuations within the fluid system. The integration of oil cooling systems in high-performance electric motorcycles has created demand for precision-molded holders that can accommodate complex geometries while maintaining leak-proof sealing interfaces.

  
  

• Mold Description
  Product Materials:	PU FOAM
  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
  

  Cell Holder PU Foam Molding

  The Cell Holder PU Foam Molding refers to precision-molded components manufactured from rigid polyurethane (PU) foam, designed to house and protect individual lithium-ion battery cells within a battery pack. These cell holders are precisely manufactured, rigid, flame-retardant, closed-cell polyurethane foam structures. The closed-cell structure acts as an insulator and gas barrier to minimize conduction and convection between battery cells, effectively isolating neighboring cells to protect against thermal runaway conditions. The PU foam molding technology produces components with a solid skin layer over a microcellular foam core, enabling high-quality, durable parts with improved strength-to-weight ratios. Cell holders may also contain nested busbars for connecting sections of the battery pack.

   

  The PU foam (Polyurethane foam) is a synthetic polymer material formed by the reaction of isocyanate and polyol components. For battery holder applications, rigid PU foam formulations are specifically engineered to provide:

   

  Electrical insulation to prevent short circuits between adjacent cells

   

  Mechanical protection against vibration and impact

   

  Thermal management to dissipate heat and maintain optimal operating temperatures

   

  Dimensional accuracy for proper cell alignment

   

  Flame retardancy (UL94 V-0 rated) for safety compliance

   

  The PU foam is a flame-retardant and thermally insulating material. When selecting materials for foam cell holders, various properties are considered including mechanical stiffness (modulus of elasticity, yield strength), minimized thermal conductivity, amenability to adhesive bonding, high dielectric constant, high resistance to dielectric breakdown, low density (low weight), and mass manufacturing capability. The material must also be resistant to water absorption and fungal growth, self-extinguishing, and flame resistant.

• Raw Material Technical Characteristics and TDS

  PU Foam Material Composition

  Rigid polyurethane foam for battery holder applications is produced from a two-component system comprising:

   

  Isocyanate Component (A-Side): Polymeric MDI (Methylene Diphenyl Diisocyanate) or modified isocyanates that provide the reactive functionality for foam formation. The isocyanate index and functionality determine the crosslink density and ultimate mechanical properties of the cured foam.

   

  Polyol Component (B-Side): A blend of polyether or polyester polyols, catalysts, blowing agents, surfactants, and flame retardant additives. The polyol formulation dictates the foam's density, cell structure, and physical properties.

   

  Key Additives:

   

  Catalysts: Amine and organometallic compounds that control the reaction kinetics of urethane formation and blowing reactions

   

  Blowing Agents: Physical or chemical agents that generate the cellular structure

   

  Surfactants: Silicone-based compounds that stabilize cell formation and control cell size

   

  Flame Retardants: Phosphorus-based or halogenated compounds that impart UL94 V-0 rating

   

  Fillers: Glass fibers or mineral fillers for enhanced mechanical properties

   

  Technical Data Sheet (TDS) - Rigid PU Foam for Cell Holders

  Based on industry standards and typical specifications for rigid PU foam battery holder applications:

   

  Property Value Test Method

  Physical Properties

  Density Range 200 - 1200 kg/m³ ASTM D1622

  Closed Cell Content ≥ 90% ASTM D2856

  Water Absorption < 2% by volume ASTM D2842

  Mechanical Properties

  Compressive Strength 2.0 - 8.0 MPa ASTM D1621

  Tensile Strength 3.0 - 7.0 MPa ASTM D1623

  Flexural Modulus 100 - 500 MPa ASTM D790

  Elongation 10 - 70% ASTM D638

  Thermal Properties

  Operating Temperature Range -50°C to +150°C

  Thermal Conductivity 60 - 70 mW/m·K ASTM C518

  Heat Deflection Temperature 100 - 130°C ASTM D648

  Electrical Properties

  Dielectric Strength ≥ 600 kV/mm ASTM D149

  Surface Resistivity > 10¹³ Ω ASTM D257

  Flammability

  UL Rating UL94 V-0 UL94

  Oxygen Index > 26% ASTM D2863

  Alternative Material Options for Battery Brackets

  For electric motorcycle battery brackets, Ansix Tech utilizes various engineering thermoplastics depending on application requirements:

   

  Material Key Properties Typical Application

  PPO+GF40 High dimensional stability, low moisture absorption, excellent electrical properties Battery trays requiring precision fit

  PPS+GF40 Superior chemical resistance, high temperature stability (up to 200°C), excellent creep resistance High-temperature battery applications

  PA66+GF35 High strength-to-weight ratio, good impact resistance, cost-effective Standard battery brackets

  PC/ABS Blends Excellent impact resistance, good dimensional stability, UL94 V-0 available Cell holders and battery modules

  Material Selection Criteria

  The selection of raw materials for electric motorcycle battery components involves careful consideration of multiple factors:

   

  Thermal Performance: Materials must withstand operating temperatures from -50°C to +150°C without degradation

   

  Electrical Insulation: High dielectric strength (>600 kV/mm) to prevent short circuits

   

  Flame Retardancy: UL94 V-0 rating for safety compliance in battery applications

   

  Mechanical Strength: Adequate compressive and tensile properties to support battery loads

   

  Chemical Resistance: Resistance to electrolytes, coolants, and environmental contaminants

   

  Dimensional Stability: Low coefficient of thermal expansion and minimal moisture absorption

   

  Weight Optimization: Low density to maximize vehicle range

   

  Manufacturing Feasibility: Compatibility with injection molding or foam molding processes

   

  Part III: Ansix Tech - Custom Material Development and Manufacturing Excellence

  Company Overview and Capabilities

  Ansix Tech, established in Hong Kong in 1998, has emerged as a precision injection molding specialist with over 29 years of manufacturing experience. The company 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. The machine fleet includes premium global brands including Japan's Fanuc, Sumitomo, Toshiba, Nissei, Engel, Germany's Arburg, and China's Haitian and Victor Taichung Machinery.

   

  Precision Manufacturing Infrastructure

  Ansix Tech's manufacturing capability begins with its state-of-the-art equipment portfolio:

   

  Five-Axis High-Speed Machining Centers: Capable of achieving 0.002mm precision on complex curved surfaces. This capability ensures that product parting lines remain smooth and burr-free—a critical aesthetic and functional requirement for battery components that must interface seamlessly with battery modules. For cylindrical battery foam holders, this translates directly to parting lines that are smooth and flash-free, eliminating costly manual deflashing operations.

   

  Slow-Wire EDM (Electrical Discharge Machining): Capable of machining features as fine as 0.03mm in width for micro-pores and narrow slots. This precision prevents thin-wall deformation during both machining and subsequent molding operations.

   

  High-Precision Grinding and Polishing Equipment: Achieving surface roughness values as low as Ra 0.05μm for cavity and core surfaces.

   

  Multi-Stage Double-Taper Positioning Technology: For multi-cavity molds, maintaining perfect concentricity between core and cavity with eccentricity within 0.05mm.

   

  Custom Material Development and Formulation

  Ansix Tech's expertise extends beyond manufacturing to include custom material development. The company undertakes raw material custom formulation projects to address specific customer requirements:

   

  Value Proposition of Custom Material Development:

   

  Application-Specific Formulations: Ansix develops PU foam formulations tailored to specific battery chemistries, operating conditions, and performance requirements. Custom formulations can optimize density, cell structure, thermal conductivity, and flame retardancy for particular applications.

   

  Performance Optimization: Through systematic material characterization and testing, Ansix fine-tunes formulations to achieve optimal mechanical properties, thermal stability, and electrical insulation. The company's SHOKLESS™-compatible foam systems can deliver robust mechanical properties at different operating temperatures.

   

  Cost-Effective Solutions: Custom material development enables cost optimization by selecting the most appropriate raw materials for each application rather than over-specifying or using generic formulations. Material utilization rates exceed 90%, minimizing waste.

   

  Regulatory Compliance: Ansix ensures that custom formulations meet relevant industry standards including UL94 V-0 flame retardancy, RoHS compliance, and REACH requirements.

   

  Sustainability: Custom formulations can incorporate recycled content and be developed according to mass balance principles to support customers' carbon footprint reduction efforts.

   

  Material Verification and Quality Validation

  Ansix Tech implements comprehensive material verification and quality validation protocols:

   

  Raw Material Incoming Inspection: All raw materials undergo rigorous incoming inspection including:

   

  Chemical composition verification

   

  Viscosity and reactivity testing

   

  Moisture content analysis

   

  Batch-to-batch consistency verification

   

  Process Validation:

   

  Design of Experiments (DOE): Systematic variation of process parameters to identify optimal molding conditions

   

  First Article Inspection (FAI): Comprehensive dimensional and functional verification of first production parts

   

  Process Capability Studies: CPK (Process Capability Index) maintained at ≥ 1.33 for critical dimensions—the automotive industry gold standard

   

  Quality Inspection Infrastructure:

   

  CMM (Coordinate Measuring Machines): For precise dimensional verification

   

  Optical Imaging Systems: For surface quality and defect detection

   

  Full Dimensional Reporting: Every mold undergoes full dimensional reporting before shipment

   

  Cost Reduction Strategies

  Ansix Tech implements multiple strategies to reduce customer costs:

   

  1. Material Cost Optimization:

   

  Multi-cavity hot runner systems reduce material waste by eliminating runner scrap, translating to 15-20% material cost savings per part

   

  Material utilization rates exceed 90%, minimizing waste

   

  2. Process Efficiency:

   

  All-servo electric drives deliver stable process repeatability of ±0.1% variation from shot to shot, minimizing scrap and rework

   

  Optimized molding cycles reduce per-part production time

   

  Stack molds double cavity count within the same machine footprint, increasing output by 100% on identical machine hours—effectively halving per-part machine cost

   

  3. Tooling Investment Protection:

   

  Mold lifespan guaranteed at 500,000 shots for glass fiber-reinforced materials and 1,000,000 shots for standard engineering plastics

   

  Strategic material selection and heat treatment protocols deliver years of uninterrupted production

   

  4. Reduced Secondary Operations:

   

  Flash-free molding eliminates costly manual deflashing operations

   

  Optical-grade surface finishes on mold cavities eliminate secondary polishing operations

   

  5. Single-Source Supply:

   

  Comprehensive capabilities from mold design to production eliminate coordination costs and delays between suppliers

   

  Capacity Enhancement and Delivery Assurance

  Production Capacity:

   

  260 injection molding machines across four manufacturing campuses

   

  Clamping force range from 30 tons to 4,000 tons

   

  Capability to handle product portfolios of any size on a single production line

   

  Delivery Assurance:

   

  Full servo-motor drive systems ensure batch-to-batch consistency

   

  First part and millionth part are identical—no dimension drift, no assembly issues

   

  Complete traceability with material certification reports and heat treatment curves

   

  Part IV: Application Fields and Product Advantages

  Primary Application Areas

  Electric Motorcycle Battery Systems:

   

  Electric motorcycle battery brackets and cell holders are fundamental components in battery pack assemblies. The battery bracket securely mounts the battery pack to the vehicle frame, while cell holders organize and protect individual battery cells within the pack. These components are essential for:

   

  Cylindrical Cell Battery Packs: Precision-molded foam holders designed to house and protect cylindrical lithium-ion cells

   

  Prismatic Cell Battery Packs: Holders and brackets for rectangular battery cells

   

  Pouch Cell Battery Packs: Support structures for flexible pouch-type cells

   

  Energy Storage Systems:

   

  Stationary energy storage battery racks and holders

   

  Portable power station battery cell holders

   

  Backup power system battery brackets

   

  Electric Two-Wheel and Three-Wheel Vehicles:

   

  Electric scooters and e-bikes

   

  Electric three-wheelers and cargo vehicles

   

  Automotive Applications:

   

  Electric vehicle battery trays and cell holders

   

  Hybrid vehicle battery components

   

  Product Advantages and Functional Benefits

  1. Thermal Management:

  PU foam cell holders with closed-cell structure act as thermal insulators, minimizing heat transfer between adjacent cells. This prevents thermal runaway propagation and maintains uniform temperature distribution across the battery pack. The foam's thermal conductivity of 60-70 mW/m·K provides effective thermal isolation.

   

  2. Electrical Safety:

  With dielectric strength exceeding 600 kV/mm, PU foam cell holders provide excellent electrical insulation between cells. The high dielectric constant and resistance to dielectric breakdown prevent short circuits and ensure safe operation.

   

  3. Vibration and Shock Protection:

  PU foam's microcellular structure provides superior energy absorption, protecting battery cells from vibration and impact damage. The foam systems help safeguard the structural integrity of batteries in case of impact.

   

  4. Weight Reduction:

  With densities ranging from 200 to 1200 kg/m³, PU foam cell holders offer significant weight savings compared to metal alternatives. Lightweight foam technology reduces overall vehicle weight, extending driving range.

   

  5. Dimensional Precision:

  Precision-molded foam holders achieve tight dimensional tolerances for proper cell alignment. Accurate cell positioning ensures consistent electrical connections and optimal thermal management.

   

  6. Fire Safety:

  UL94 V-0 rated flame retardancy provides critical fire protection in battery applications. The material is self-extinguishing and flame resistant.

   

  7. Chemical and Environmental Resistance:

  PU foam cell holders resist water absorption and fungal growth. The closed-cell structure provides excellent barrier properties against moisture and contaminants.

   

  8. Manufacturing Efficiency:

  PU foam molding enables the production of complex shapes with minimal waste. Casting processes can create durable, lightweight structures without extensive post-machining.

   

  Specific Component Applications

  Battery Brackets:

   

  Mount battery packs securely to vehicle frames

   

  Provide structural support for heavy battery assemblies

   

  Enable quick battery removal for maintenance or replacement

   

  Accommodate various battery sizes and configurations

   

  Cell Holders:

   

  Organize individual cells in precise geometric arrays

   

  Isolate cells to prevent thermal runaway propagation

   

  Provide mechanical protection for sensitive cell components

   

  Enable busbar integration for electrical connections

   

  Oil Cell Holders:

   

  Secure oil reservoirs and cooling components

   

  Withstand exposure to oils and coolants

   

  Maintain sealing integrity under pressure

   

  Support thermal management systems

   

  Part V: Manufacturing Process Excellence

  Mold Design and Engineering

  Ansix Tech's mold design process incorporates advanced engineering methodologies:

   

  Moldflow Analysis (DFM): Comprehensive flow simulation to optimize gate locations, predict filling patterns, and identify potential defects. This analysis ensures:

   

  Optimal cavity filling

   

  Minimized weld lines and air traps

   

  Balanced flow distribution

   

  Reduced warpage and shrinkage

   

  Cooling System Design: Strategic placement of cooling channels to achieve uniform temperature distribution and minimize cycle times. Features include:

   

  Conformal cooling channels for complex geometries

   

  Baffle plates for enhanced heat transfer

   

  Water cooling systems for efficient heat extraction

   

  Gating System Design: Selection of optimal gate types and locations including:

   

  Hot runner systems for reduced material waste

   

  Direct gates, edge gates, and fan gates for different geometries

   

  Multi-point gating for large parts

   

  Ejection System Design: Reliable ejection mechanisms including:

   

  Ejector pins for flat surfaces

   

  Sleeve ejectors for cylindrical features

   

  Air ejection for delicate components

   

  Mold Manufacturing Process

  Material Selection for Molds:

   

  Component Material Options Properties

  Mold Base P20, 718H Structural integrity, corrosion resistance

  Core/Cavity S136, 2344, 2343, 8407, SKD11/61, DC53, M340, 4Cr13, 9Cr18, NAK80, H13 Wear resistance, thermal stability

  Wear Components Hardened tool steels Extended service life

  Manufacturing Workflow:

   

  CAD Modeling: 3D design of mold components

   

  CAM Programming: Toolpath generation for CNC machining

   

  Rough Machining: Material removal to approximate shape

   

  Heat Treatment: Hardening to achieve required wear resistance

   

  Finish Machining: Precision machining to final dimensions

   

  EDM: Electrical discharge machining for fine features and complex geometries

   

  Grinding and Polishing: Surface finishing to Ra 0.05μm or better

   

  Assembly: Integration of all mold components

   

  Testing and Validation: Trial molding and process optimization

   

  Injection Molding Process Optimization

  Process Parameters:

   

  Temperature Control: Precise barrel, nozzle, and mold temperature regulation

   

  Injection Pressure: Optimized for complete cavity filling without flash

   

  Injection Speed: Controlled to prevent material degradation and ensure uniform filling

   

  Cooling Time: Minimized while maintaining dimensional stability

   

  Holding Pressure: Applied to compensate for material shrinkage

   

  Quality Control During Production:

   

  In-process dimensional monitoring

   

  Visual inspection for surface defects

   

  Mechanical property testing of sample parts

   

  Statistical process control (SPC) for critical dimensions

   

  PU Foam Molding Process

  The PU foam molding process for cell holders involves:

   

  Material Preparation: Precise metering of isocyanate and polyol components

   

  Mixing: High-speed mixing to achieve homogeneous reaction mixture

   

  Dispensing: Controlled dispensing into the mold cavity

   

  Foaming: Chemical reaction generating cellular structure

   

  Curing: Completion of polymerization and foam stabilization

   

  Demolding: Part removal after sufficient cure

   

  Finishing: Minimal trimming due to flash-free molding

   

  Part VI: Industry Experience and Reliability

  Proven Track Record

  Ansix Tech's 29+ years of manufacturing experience have established the company as a trusted partner for electric motorcycle and automotive battery component manufacturing. The company has successfully developed complex mold projects including:

   

  Cylindrical battery foam holders with precision-molded features

   

  New energy battery trays for automotive applications

   

  Energy storage battery cell holders

   

  Custom PU foam molding for various battery configurations

   

  Customer Value Proposition

  Reliability: With 260 injection molding machines and comprehensive quality systems, Ansix delivers consistent quality across millions of production cycles. CPK ≥ 1.33 ensures 99.9937% of features within specification.

   

  Innovation: Custom material development capabilities enable tailored solutions for specific applications. The company's expertise in PU foam molding and injection molding provides flexible manufacturing options.

   

  Cost Efficiency: Through material optimization, process efficiency, and tooling investment protection, Ansix significantly reduces total cost of ownership for customers.

   

  Speed: Rapid prototyping and production capabilities accelerate time-to-market. Comprehensive capabilities from design to delivery eliminate supply chain friction.

   

  Quality: Full traceability with material certification reports and heat treatment curves ensures complete quality assurance.

   

  Conclusion

  The electric motorcycle battery bracket, oil cell holder, and cell holder PU foam molding industries are experiencing rapid evolution driven by the growth of electric mobility. These components represent critical interfaces between battery systems and vehicle structures, requiring advanced materials, precision manufacturing, and rigorous quality control.

   

  Industry leaders like Ansix Tech are advancing the field through custom material development, state-of-the-art manufacturing capabilities, and comprehensive quality systems. With over 29 years of experience, 260 injection molding machines, and precision machining capabilities achieving 0.002mm accuracy, Ansix delivers reliable, cost-effective solutions for electric motorcycle battery component manufacturing.

   

  The company's expertise in custom PU foam formulation, injection molding process optimization, and quality validation enables customers to achieve optimal performance, safety, and cost efficiency. Through strategic material selection, process optimization, and tooling investment protection, Ansix reduces customer costs while ensuring consistent quality and reliable delivery.

   

  As the electric motorcycle market continues to grow, the demand for high-quality battery brackets, cell holders, and specialized components will increase correspondingly. Companies with comprehensive manufacturing capabilities, material development expertise, and proven quality systems will be well-positioned to meet this demand and drive innovation in electric mobility components.

   

  This industry news report is based on publicly available information and industry standard specifications. For specific technical data and custom solutions, please contact manufacturers directly.

   

   

  Ansix Tech: Comprehensive Manufacturing Solutions for Electric Motorcycle Battery Brackets, Oil Cell Holders, and Cell Holder PU Foam Molding

  Executive Summary

  Ansix Tech Co., Ltd., established in Hong Kong in 1998, has evolved over 28 years into a leading one-stop plastic injection molding solution provider. Operating four production bases across China and Vietnam with over 200,000 square meters of manufacturing space, Ansix employs more than 1,200 people including over 200 engineers and designers, and has successfully delivered over 30,000 mold sets. The company holds ISO9001, ISO14001, IATF16949, ISO13485, and BSCI certifications.

   

  This document provides a comprehensive overview of how Ansix Tech delivers exceptional value across electric motorcycle battery bracket, oil cell holder, and cell holder PU foam molding products—translating technical capabilities into measurable customer value rather than simply selling tooling.

   

  PART ONE: Hard Power Infrastructure — Building Customer Trust Through Equipment Excellence

  1.1 Mold Processing Equipment

  Ansix Tech's mold manufacturing capabilities are built on a foundation of world-class precision equipment:

   

  Five-Axis High-Speed Machining Centers: Capable of machining complex curved surfaces with 0.002mm precision. For battery bracket and cell holder products, this translates directly to:

   

  Smooth, burr-free parting lines on every product—eliminating costly manual deflashing operations

   

  Zero secondary finishing operations required—reducing post-processing costs by up to 15%

   

  Consistent part-to-part fit that eliminates assembly issues

   

  Slow-Wire EDM (Electrical Discharge Machining): Capable of machining features as fine as 0.03mm for micro-pores and narrow slots. This is critical for:

   

  Thin-wall sections where deformation must be prevented

   

  Intricate geometries with precision that prevents distortion

   

  Lighter-weight designs without compromising structural integrity

   

  High-Precision Grinding and Polishing Equipment: Achieving surface roughness values as low as Ra 0.05μm for cavity and core surfaces.

   

  Multi-Stage Double-Taper Positioning Technology: For multi-cavity molds, maintaining perfect concentricity between core and cavity with eccentricity within 0.05mm.

   

  Customer Value: "We ensure your product's parting lines are smooth and burr-free, eliminating manual finishing operations that add cost and delay. Our precision machining means your complex battery bracket geometries are manufactured right the first time."

   

  1.2 Injection Molding Machine Fleet

  Ansix operates 260 injection molding machines with clamping forces ranging from 30 tons to 4,000 tons. This extensive range covers product sizes from micro-scale components under 1 gram to large automotive parts exceeding several kilograms.

   

  Machine Brands: The fleet includes premium global brands including Japan's Fanuc, Sumitomo, Toshiba, Nissei, Engel, Germany's Arburg (primarily for liquid silicone injection molding), and domestic machines from 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.

   

  Capability Specification Customer Value

  Clamping Force Range 30 – 4,000 tons Covers every product size from small cell holders to large battery pack casings

  Drive System All-electric servo motors Energy consumption reduced by 40–80%

  Repeatable Precision ±0.1% shot-to-shot The 10,000th part is identical to the first

  Machine Networking Full MES integration Real-time monitoring of all key process parameters

  Customer Value: "With 260 machines across four production bases, we have the capacity to scale from prototyping to millions of units per month without re-tooling or capacity bottlenecks. Every machine is servo-driven for energy efficiency and consistent quality—you never worry about batch-to-batch variation."

   

  1.3 Inspection and Metrology Equipment

  Ansix maintains a comprehensive quality inspection infrastructure:

   

  Coordinate Measuring Machines (CMM) with 0.001mm resolution

   

  High-precision optical measurement systems with sub-micron resolution

   

  Full dimensional compliance reports for every mold before shipment

   

  Critical-to-quality features achieving Cpk ≥ 1.33 — a statistical guarantee that 99.993% of production falls within specification limits

   

  Customer Value: "We don't just ship molds—we ship confidence. Every mold comes with a comprehensive First Article Inspection (FAI) report, often exceeding 200 data points for complex components. Our Cpk ≥ 1.33 guarantee means your assembly lines will never experience fit issues due to out-of-tolerance parts."

   

  PART TWO: Core Mold Manufacturing Competencies — Quantifiable Value Delivery

  2.1 Mold Steel Selection and Life Expectancy

  The fundamental client question centers on mold longevity: how many cycles before costly rework or replacement becomes necessary?

   

  Mold Steel Selection Framework:

   

  Component Steel Grades Properties Application Value

  Mold Base P20 (1.2311) Pre-hardened, excellent machinability Cost-effective structural foundation

  Cavity/Core (Standard Plastics) NAK80 / S136H High polishability, good wear resistance ≤500,000 cycles

  Cavity/Core (Glass-Filled Materials) S136 / H13 / SKD61 Superior wear resistance, thermal stability ≥500,000 cycles

  High-Wear Inserts Tungsten Carbide / DC53 Extreme hardness, abrasion resistance Extended life in high-wear areas

  Comprehensive Options S136, 2344, 2343, 8407, SKD11/61, DC53, M340, 4Cr13, 9Cr18, NAK80, H13 Material-specific selection optimizes wear and corrosion resistance Tailored to each application

  Guaranteed Mold Life:

   

  500,000 shots for glass-fiber reinforced materials

   

  1,000,000 shots for standard plastics

   

  Customer Value: Longest possible production run before maintenance; lower cost-per-part over mold lifetime. Complete material certification reports and heat treatment curves provided for full traceability and quality audits.

   

  2.2 Achievable Tolerances

  Product Type Achievable Tolerance Customer Value

  Standard structural parts ±0.05mm Meets automotive specifications

  Precision gears/medical components ±0.005mm Eliminates rework and fit issues

  Parting line precision 0.005mm Flash controlled within 0.03mm—eliminates manual deflashing

  Critical dimensions Cpk ≥ 1.33 99.993% within specification

  2.3 Mold Types and Capabilities

  Ansix offers a comprehensive range of mold technologies:

   

  Hot Runner Systems: Reduce material waste by eliminating runner scrap. For large battery tray components, this translates to 15-20% material cost savings per part.

   

  Stack Molds: Double cavity count within the same machine footprint, increasing output by 100% on identical machine hours—effectively halving per-part machine cost.

   

  Two-Shot/Multi-Material Molds: Enable overmolding of different materials in a single cycle, eliminating secondary assembly operations.

   

  High-Cavity Molds: Ansix has successfully designed and manufactured 16-cavity, 32-cavity, and 128-cavity injection molds.

   

  2.4 Gate and Cooling System Design

  Mold Flow Analysis (MFA): Ansix utilizes Autodesk Moldflow simulation software for comprehensive DFM analysis, predicting weld-line and gas trap positions before steel is cut.

   

  Gate Optimization:

   

  Gate number and position optimized for balanced cavity filling

   

  Shrinkage compensation based on material-specific data

   

  Elimination of flow imbalance that causes dimensional variation

   

  Cooling System Design:

   

  Uniform temperature distribution through strategic cooling channel layout

   

  Mold temperature zoning with core and cavity temperature differential controlled within 2°C to reduce warpage and residual stress

   

  Water cooling standard; conformal cooling available for complex geometries

   

  Customer Value: "We design the cooling system, gate locations, and ejection system specifically for high-volume production—ensuring your mold arrives at your production line ready for immediate, trouble-free operation."

   

  2.5 Mold Manufacturing Process and Lead Times

  Standard Lead Times:

   

  Simple molds: 10 days

   

  Medium complexity molds: 25-45 days

   

  Expedited service: Medium-complexity molds compressed to 20 days without compromising validation protocols

   

  In-House Manufacturing Advantage: Ansix's integrated in-house mold manufacturing and injection molding operations eliminate the common industry pain point of mold transfer delays between separate workshops. With self-built electrode machining centers and EDM workshops, mold repairs and modifications are completed without leaving the factory—routine welding/insert replacement restored to production within 24 hours.

   

  Pre-Delivery Validation: Every mold undergoes a 2000-shot wear test before delivery, with detailed wear reports provided.

   

  PART THREE: Injection Molding Process Control — Eliminating Quality Anxiety

  3.1 Process Standardization and Control

  MES-Integrated Process Locking: All machines are networked with成型 parameters (temperature, pressure, speed, time) locked in the MES system—only authorized engineers can make adjustments. First and last article inspection for every batch ensures consistency.

   

  Closed-Loop Monitoring:

   

  Real-time monitoring of melt temperature, injection pressure, and holding pressure

   

  In-mold temperature and pressure sensors for closed-loop control

   

  Ultrasonic wall thickness sensors providing real-time feedback and automatic compensation

   

  Size Stability Control: For battery bracket products, continuous production across three batches within one week shows key hole spacing variation ≤ 0.02mm.

   

  3.2 Appearance Quality Grades

  Requirement Achievable Standard Application

  Transparent parts Bubble-free, flow-mark-free Clear components

  Plated parts No gas marks Cosmetic surfaces

  High-gloss surfaces Surface roughness Ra ≤ 0.2μm Visible exterior components

  Printed/coated parts Registration tolerance ±0.1mm Branded components

  3.3 Special Material Processing Capabilities

  Ansix has extensive production experience with engineering-grade materials:

   

  Thermoplastics:

   

  PC/ABS, PC, PPS+40%GF, PEEK, PTFE/PFA

   

  PA6+GF30, PBT, PEI/PPS/LCP

   

  PPO+GF40, PA66+GF35

   

  PPO+GF30

   

  Liquid Silicone Rubber (LSR): Specialized Arburg two-component LSR injection molding machines

   

  PU Foam: Rigid PU foam molding producing structural foam components with a solid skin layer over a microcellular foam core

   

  Key Material Properties:

   

  Flame retardancy: UL94 V-0 rated for safety compliance

   

  Temperature range: -50°C to 150°C

   

  Weather resistance: UV testing 3000 hours without color change

   

  3.4 Addressing Common Customer Concerns

  Customer Complaint Ansix's Solution

  Frequent mold repairs affecting orders 2000-shot wear test pre-delivery; three-year structural warranty on mold frames (excluding normal wear parts)

  Excessive flash increasing finishing costs 0.005mm parting line fit tolerance; self-locking clamp force compensation; flash controlled within 0.03mm

  Inconsistent dimensions batch-to-batch Servo-driven machines with ±0.1% repeatability; MES-locked parameters; closed-loop process control

  Long repair lead times In-house EDM and electrode workshops; 24-hour repair recovery

  3.5 Mold Flow Analysis (DFM) and Early Intervention

  Pre-Contract DFM Report Includes:

   

  Draft angle recommendations

   

  Wall thickness optimization

   

  Gate location and number

   

  Ejector pin mark location allowances

   

  Weld-line and gas trap prediction

   

  Shrinkage compensation based on material-specific data

   

  Customer Value: "We identify and resolve manufacturing risks before steel is cut—preventing the discovery of unmanufacturable designs after the mold is already built."

   

  PART FOUR: Full-Service Lifecycle Support — Reducing Customer Management Costs

  4.1 Early Engineering Engagement

  DFM Report Before Contract Signing: Comprehensive mold feasibility analysis including:

   

  Part design review for manufacturability

   

  Material selection recommendations

   

  Processing parameter projections

   

  Cost optimization suggestions

   

  Prototype to Production: From prototype design confirmation through to mass production and assembly validation.

   

  4.2 Trial Molding and Sampling

  T0 to T3 Trial Samples: Progressive mold trials with improvement reports for each round. Quick-change inserts enable testing of different design variations without rebuilding the entire mold.

   

  4.3 Small-Batch Validation

  100-500 Shot Pre-Production Run: Statistical yield and Cpk analysis performed to confirm process stability before full production release.

   

  4.4 Maintenance and Spare Parts

  Spare Parts Package: Wear parts (ejector pins, core inserts) delivered with the mold.

   

  Scheduled Maintenance: Maintenance service every 200,000 cycles.

   

  Lifetime Support: Lifetime repair at cost price.

   

  Customer Value: "We don't just deliver a mold and disappear. We provide ongoing support throughout the entire lifecycle of your product."

   

  PART FIVE: Product-Specific Manufacturing Solutions

  5.1 Electric Motorcycle Battery Bracket

  Product Characteristics:

   

  Structural mounting component for battery packs

   

  Must withstand vibration, impact, and thermal cycling

   

  High dimensional accuracy required for proper fit with frame and battery modules

   

  Material Selection: PPO+GF40, PA66+GF35, or PPS+GF40 depending on thermal and mechanical requirements

   

  Manufacturing Approach:

   

  Hot runner systems for material savings (15-20% reduction)

   

  Precision mold design with 0.002mm machining accuracy

   

  CPK ≥ 1.33 on all critical mounting hole positions

   

  UL94 V-0 flame retardancy compliance

   

  5.2 Oil Cell Holder

  Product Characteristics:

   

  Chemical resistance to oils and lubricants

   

  Dimensional stability across temperature range

   

  Precision fit for cell positioning

   

  Manufacturing Approach:

   

  Material selection optimized for chemical resistance

   

  Precision machining for tight tolerances

   

  Comprehensive testing for chemical compatibility

   

  5.3 Cell Holder PU Foam Molding

  Product Characteristics:

   

  Cylindrical battery foam holders designed to house and protect sensitive lithium-ion battery cells

   

  Must provide: electrical insulation, mechanical protection, thermal management, dimensional accuracy, flame retardancy

   

  Rigid PU Foam Properties:

   

  Solid skin layer over microcellular foam core

   

  Improved strength-to-weight ratio

   

  Temperature range: -50°C to 150°C

   

  Closed cell content optimized for insulation

   

  Manufacturing Specifications:

   

  Mold Material: S136ESR

   

  Number of Cavities: 1

   

  Feeding Method: Hot runner

   

  Cooling Method: Water cooling

   

  Molding Cycle: 42.5 seconds

   

  PART SIX: Competitive Advantages — Addressing Industry Pain Points with Actionable Guarantees

  6.1 Cost Control

  Material Cost Reduction:

   

  Hot runner systems reduce runner waste by 15-20%

   

  Scientific material selection matching performance to application

   

  Process Efficiency:

   

  Stack molds increase output by 100% on same machine hours

   

  Servo-driven machines reduce energy consumption by 40-80%

   

  Cycle time optimization lowers per-part cost

   

  Quality Cost Avoidance:

   

  Zero secondary finishing required—eliminating manual deflashing operations

   

  CPK ≥ 1.33 virtually eliminates scrap and rework

   

  In-house mold repair within 24 hours—minimizing downtime

   

  Tooling Investment Optimization:

   

  Family molds reduce tooling investment

   

  500,000-1,000,000 shot mold life maximizes ROI

   

  6.2 Delivery Efficiency

  Fast Time-to-Market:

   

  Simple molds: 10 days

   

  Medium complexity: 25-45 days

   

  Expedited: 20 days without compromising validation

   

  Scalable Production Capacity:

   

  260 injection molding machines across four production bases

   

  Capacity from prototype to millions of units per month

   

  No capacity bottlenecks or re-tooling delays

   

  In-House Integration:

   

  Mold manufacturing and injection molding under one roof

   

  Eliminates mold transfer delays between separate workshops

   

  Faster iteration and modification cycles

   

  6.3 Quality Assurance

  Comprehensive Quality System:

   

  ISO9001, ISO14001, IATF16949, ISO13485, BSCI certified

   

  Full dimensional reporting for every mold before shipment

   

  Critical dimensions: CPK ≥ 1.33 guarantee

   

  Process Validation:

   

  2000-shot pre-delivery wear test with detailed report

   

  T0 to T3 trial samples with improvement reports

   

  Small-batch validation (100-500 shots) with statistical analysis

   

  Traceability:

   

  Material certification reports and heat treatment curves provided

   

  Complete traceability for automotive industry compliance

   

  6.4 After-Sales Service

  Warranty:

   

  Three-year structural warranty on mold frames (excluding normal wear parts)

   

  Maintenance:

   

  Spare wear parts delivered with the mold

   

  Maintenance service every 200,000 cycles

   

  Lifetime repair at cost price

   

  Emergency Support:

   

  24-hour in-house repair service

   

  Self-built electrode and EDM workshops ensure rapid turnaround

   

  PART SEVEN: Material Selection and Characteristics

  7.1 Thermoplastic Materials for Battery Components

  Material Key Properties Typical Application

  PPO+GF40 High dimensional stability, low moisture absorption Battery trays, brackets

  PA66+GF35 High strength, good chemical resistance Structural components

  PPS+40%GF High temperature resistance, chemical resistance High-heat applications

  PPO+GF30 Good electrical properties, flame retardant Cell holders

  PC/ABS Impact resistance, good appearance Housings, covers

  PBT Good electrical properties, dimensional stability Connectors, insulators

  PA6+GF30 High strength, toughness Structural parts

  7.2 PU Foam Material Properties

  Rigid PU foam molding produces structural foam components with specific technical characteristics:

   

  Property Specification Value

  Temperature Range Operating range -50°C to 150°C

  Cell Structure Closed cell content Optimized for insulation

  Flame Retardancy UL94 rating V-0

  Strength-to-Weight Structural foam Improved ratio

  7.3 Mold Steel Material Specifications

  Mold Base Steel:

   

  P20 (1.2311): Pre-hardened, excellent machinability, cost-effective

   

  Cavity and Core Steels:

   

  S136: High polishability, corrosion resistance

   

  2344, 2343: Hot work tool steels, good thermal stability

   

  8407: High toughness, good wear resistance

   

  SKD11/61, DC53: High wear resistance, good for glass-filled materials

   

  M340, 4Cr13, 9Cr18: Stainless grades for corrosion resistance

   

  NAK80: Pre-hardened, excellent polishability

   

  H13: High temperature resistance, thermal stability

   

  ESR (Electro-Slag Remelting) Grades: S136ESR specified for critical applications requiring superior purity and polishability

   

  Conclusion: Why Ansix Tech

  For Ansix Tech, a mold is not just a piece of steel—it is a revenue-generating asset. Every mold is designed with careful planning for:

   

  Flow characteristics ensuring balanced filling

   

  Venting paths eliminating gas traps and burns

   

  Temperature balance minimizing warpage and residual stress

   

  The result: a mold that arrives at your production line ready for immediate, trouble-free operation—with low flash, long life, and consistent quality.

   

  Core Value Proposition:

   

  Customer Need Ansix's Solution Measurable Benefit

  Lower part cost Hot runner systems, stack molds, energy-efficient servo drives 15-20% material savings, 40-80% energy reduction

  Faster time-to-market 10-45 day mold lead times, in-house manufacturing Weeks saved in development cycle

  Consistent quality ±0.1% repeatability, CPK ≥ 1.33, MES-locked processes 99.993% within specification

  Longer mold life Premium steel selection, 500K-1M shot guarantee Lower cost-per-part over lifetime

  Reduced risk DFM analysis, 2000-shot wear test, three-year warranty No costly surprises in production

  Ongoing support Spare parts, maintenance schedule, 24-hour repairs Minimized downtime

  Ansix Tech invites customers to experience the full-service manufacturing solution—from DFM analysis through to production and after-sales support—delivering reliability, value, and peace of mind for every electric motorcycle battery bracket, oil cell holder, and cell holder PU foam molding project.

   

   

   

   

  Ansix Tech Co Ltd

  If you have any plans related to Electric motorcycle battery bracket, oil cell holder and cell holder , 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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• 

• Oil Cell Holder

  The Oil Cell Holder (also referred to as oil cell bracket or reservoir holder) is a specialized component used in hybrid or oil-cooled electric motorcycle systems. In certain electric motorcycle architectures, oil is utilized as a cooling medium for battery cells or power electronics. The oil cell holder provides a secure mounting structure for oil reservoirs, oil filters, or oil cooling cells within the vehicle. These holders must exhibit excellent chemical resistance to oils and coolants, thermal stability across operating temperature ranges, and mechanical strength to withstand pressure fluctuations within the fluid system. The integration of oil cooling systems in high-performance electric motorcycles has created demand for precision-molded holders that can accommodate complex geometries while maintaining leak-proof sealing interfaces.

   

  Cell Holder PU Foam Molding

  The Cell Holder PU Foam Molding refers to precision-molded components manufactured from rigid polyurethane (PU) foam, designed to house and protect individual lithium-ion battery cells within a battery pack. These cell holders are precisely manufactured, rigid, flame-retardant, closed-cell polyurethane foam structures. The closed-cell structure acts as an insulator and gas barrier to minimize conduction and convection between battery cells, effectively isolating neighboring cells to protect against thermal runaway conditions. The PU foam molding technology produces components with a solid skin layer over a microcellular foam core, enabling high-quality, durable parts with improved strength-to-weight ratios. Cell holders may also contain nested busbars for connecting sections of the battery pack.

   

  The PU foam (Polyurethane foam) is a synthetic polymer material formed by the reaction of isocyanate and polyol components. For battery holder applications, rigid PU foam formulations are specifically engineered to provide:

   

  Electrical insulation to prevent short circuits between adjacent cells

   

  Mechanical protection against vibration and impact

   

  Thermal management to dissipate heat and maintain optimal operating temperatures

   

  Dimensional accuracy for proper cell alignment

   

  Flame retardancy (UL94 V-0 rated) for safety compliance

   

  The PU foam is a flame-retardant and thermally insulating material. When selecting materials for foam cell holders, various properties are considered including mechanical stiffness (modulus of elasticity, yield strength), minimized thermal conductivity, amenability to adhesive bonding, high dielectric constant, high resistance to dielectric breakdown, low density (low weight), and mass manufacturing capability. The material must also be resistant to water absorption and fungal growth, self-extinguishing, and flame resistant.