Liquid micrometer Aichi PPS housing, PPS+PTFE gears

FEATURES

• Ansix Tech: Comprehensive Manufacturing Excellence for Liquid Micrometer Aichi PPS Housing and PPS+PTFE Gears

  Executive Summary

  Ansix Tech is a premier custom plastic injection molding manufacturer with over 28 years of industry experience, specializing in high-performance engineering plastic components including Liquid Micrometer Aichi PPS housings and PPS+PTFE gears. With 260 injection molding machines across four production bases in China and Vietnam, clamping forces ranging from 30 tons to 4,000 tons, and comprehensive ISO9001, IATF16949, ISO13485, ISO14001, and BSCI certifications, Ansix Tech delivers end-to-end solutions from prototype design through high-volume production with validated quality assurance.
  
  

   

  
  

• Mold Description
  Product Materials:	PPS+GF40 PPS+GF30+PTFE Soft rubber: FKM
  Mold Material:	S136ESR
  Number of Cavities:	2+2
  Glue Feeding Method:	Hot runner
  Cooling Method:	Water cooling
  Molding Cycle	42.5s

  
  
  

• 
• The mold manufacturing process and product material selection
  

  Hard Infrastructure Foundation — Building Customer Trust Through Equipment Excellence

  1.1 Precision Mold Manufacturing Equipment

  Five-Axis High-Speed Machining Centers

   

  Ansix Tech operates state-of-the-art five-axis high-speed CNC machining centers capable of maintaining ±0.002mm contour accuracy on complex surface geometries.

   

  Customer Value Delivered: For Liquid Micrometer Aichi PPS housing components, this precision capability eliminates visible witness marks and burnishing along critical sealing interfaces and sensor mounting surfaces. Zero hand-finishing of parting lines translates directly to lower inspection costs (eliminating subjective visual review) and reduced secondary deburring operations. When mating surfaces must meet sealing integrity standards (critical for liquid micrometer applications where chemical exposure is common), 0.002mm precision means housings arrive ready for assembly—not requiring rework.

   

  Slow Wire EDM (Electrical Discharge Machining)

   

  Ansix Tech deploys slow wire EDM machines capable of cutting micro-features down to 0.03mm for fine holes and narrow slots.

   

  Customer Value Delivered: For sensor housing designs that incorporate venting ports, electrode insertion openings, or thin-walled membrane regions, wire EDM eliminates the distortion risks associated with conventional milling. The ability to produce 0.03mm narrow channels directly in the mold ensures that the molded housing will contain identical features without post-molding drilling or machining—operations historically associated with micro-cracking risk in brittle engineering plastics. For PPS+PTFE gear applications requiring ±0.01mm tolerances, EDM precision ensures fragile geometries remain intact throughout the molding cycle.

   

  In-House Electrode Manufacturing & EDM Workshop

   

  By maintaining an internal electrode processing center and EDM workshop, Ansix Tech eliminates reliance on external suppliers.

   

  Customer Value Delivered: When a mold requires repair, the entire process stays within the facility, compressing conventional 5–7 day repair cycles to guaranteed 24-hour turnaround. For critical product launch windows, this agility directly protects revenue streams and reduces production downtime.

• Injection Molding Machine Fleet

  Comprehensive Machine Range

   

  Ansix Tech operates 260 injection molding machines with clamping forces spanning 30 tons to 4,000 tons, covering everything from micro-precision components to large structural parts. Key machine brands include Japan's Fanuc, Sumitomo, Toshiba, and Nissei; Austria's Engel; Germany's Arburg (primarily for liquid silicone and two-component injection molding); and China's Haitian and Victor Taichung Machinery.

   

  Customer Value Delivered: Right-sizing machine selection means customers are not forced to pay oversized machine premiums for small parts. With 30-ton capacity available for micro-sensor housings and 4,000-ton capacity for large multi-cavity tooling, energy consumption is minimized and per-part pricing remains competitive from prototype through high-volume production.

   

  All-Servo-Electric Drive Technology

   

  The entire injection molding fleet employs all-servo-electric drive systems, delivering repeatable positioning accuracy of ±0.01mm clamping stroke and injection volume consistency within ±0.1% across consecutive cycles.

   

  Customer Value Delivered: In Liquid Micrometer Aichi PPS housing production, where dimensional consistency directly affects sensor alignment, sealing integrity, and component fit, ±0.1% repeatability means the 100,000th part matches the first. This eliminates progressive yield loss—a hidden cost often overlooked until mid-production when tool wear and machine drift combine to produce non-conforming parts. Batch-to-batch variation—a common pain point with hydraulic machines—is virtually eliminated, translating to consistent dimensional stability, reduced scrap rates, and lower total landed cost per part.

   

  MES-Connected Parameter Locking

   

  Every injection molding machine integrates with Ansix Tech's MES (Manufacturing Execution System), where critical parameters—melt temperature (±2°C window), injection pressure (±0.5 MPa tolerance), injection velocity (±2% window), holding pressure profile, and cooling time—are locked at qualified setpoints.

   

  Customer Value Delivered: Only authorized engineers can adjust parameters, eliminating operator-induced variation. For medical device and liquid handling component manufacturers required to demonstrate ongoing process control for regulatory submissions (ISO 13485, IATF 16949), MES-connected machines provide the documented repeatability that audits demand.

   

  1.3 Inspection and Metrology Equipment

  Coordinate Measuring Machines (CMM)

   

  Every mold shipped from Ansix Tech undergoes a full dimensional report comparing as-machined geometry to the original CAD model.

   

  Customer Value Delivered: Key dimensions are validated with process capability indices (Cpk) maintained at ≥1.33, ensuring that the production process is statistically capable of meeting design tolerances over long production runs. This means customers receive parts that consistently meet specifications—not just the first batch.

   

  Optical Inspection Systems

   

  High-resolution optical imaging enables rapid verification of small or complex features not easily accessed by probe-based CMM, including sealing lip geometries and fine edge details critical to sensor interface integrity.

   

  100% Vision Inspection

   

  Post-molding operations include automated degating, laser marking, and ultrasonic cleaning where required. 100% vision inspection verifies critical dimensions, surface defects, and flash height.

   

  Section 2: Mold Manufacturing — Core Competencies Measured in Customer Value

  2.1 Mold Steel Selection and Lifespan Guarantee

  Material Grade Application Customer Value

  P20 Mold base Cost-effective structural integrity

  S136, 4Cr13, 9Cr18, M340 Stainless mold cores Corrosion resistance for chemical exposure

  2344, 2343, 8407, H13 Hot work tool steel High-temperature strength for PPS processing

  SKD11, DC53 Wear-resistant components Abrasion resistance for glass-filled materials

  NAK80 High polish applications Mirror finish for aesthetic surfaces

  Customer Value Delivered: For glass-filled PPS materials that present aggressive abrasive wear, Ansix Tech specifies hardened tool steels such as H13 (HRC 48-52) or S136 stainless. For glass-filled PPS, Ansix Tech guarantees 1-million-shot mold life. For general engineering plastics, mold life extends to over 1 million shots. Material certification reports and heat treatment curves are provided with every mold.

   

  2.2 Achievable Tolerances

  Standard structural components: ±0.05mm

   

  Precision gears and medical components: ±0.005mm

   

  Complex curved surfaces: ±0.002mm contour accuracy

   

  Customer Value Delivered: For Liquid Micrometer Aichi PPS housing applications where sealing surfaces and gear mesh interfaces demand micron-level precision, ±0.005mm capability ensures leak-free operation and smooth mechanical engagement—eliminating post-molding machining and reducing assembly rework costs by up to 30%.

   

  2.3 Mold Flow Analysis (MFA) and Design Optimization

  Ansix Tech runs comprehensive mold flow analysis using advanced simulation software to optimize gate location, venting, and cooling channels before steel is cut.

   

  Customer Value Delivered:

   

  Predict weld lines and air traps before mold manufacturing—identifying and eliminating defects that would otherwise require costly mold modifications

   

  Optimize gate quantity and placement to ensure balanced filling, reducing warpage and sink marks

   

  Validate cooling channel design to minimize cycle time and ensure uniform temperature distribution

   

  Prevent short shots and incomplete filling by verifying flow length-to-wall thickness ratios

   

  For PPS materials with 40% glass fiber reinforcement, flow analysis is particularly critical due to the material's high viscosity and tendency toward fiber orientation. Ansix Tech's MFA expertise ensures glass fibers are oriented to maximize mechanical strength in critical load-bearing directions while minimizing warpage.

   

  2.4 Gate and Runner System Design

  Hot Runner Systems

  Heated manifolds operating at 310°C to 330°C are widely used to reduce pressure loss and improve surface quality.

   

  Customer Value Delivered: Hot runner systems eliminate runner waste (reducing material costs by 15–25%), shorten cycle times, and produce cleaner gate vestiges that require no secondary trimming.

   

  Gate Design

   

  Direct gates: Work best for glass-filled grades

   

  Fan gates and multi-point gates: Suitable for uniform flow distribution

   

  Submarine gates (self-degating): Preferred for automated production

   

  Valve gate hot runner systems: Reduce drool problems and shorten start-up time

   

  Customer Value Delivered: Proper gate placement and design directly impact part quality—reducing visible gate marks on cosmetic surfaces, minimizing fiber orientation-induced warpage, and ensuring consistent fill across multi-cavity tools.

   

  2.5 Cooling System Design

  PPS materials retain significant heat due to their high crystallinity and processing temperatures.

   

  Customer Value Delivered: Ansix Tech employs:

   

  Balanced cooling design using beryllium copper inserts or conformal cooling in high-heat areas to provide necessary thermal management

   

  Zone-controlled mold temperature control maintaining core and cavity temperature differentials within 2°C to reduce warpage

   

  Cycle time optimization through efficient heat extraction, reducing per-part production cost

   

  2.6 Mold Delivery Standards

  Mold Complexity Standard Lead Time Expedited Lead Time

  Simple molds 10 working days 5–7 days

  Medium complexity 25–45 working days 20 days

  High complexity (multi-cavity, hot runner) 45–60 working days 30–35 days

  Sample quantities are delivered in 7–10 days, and mass production orders (100k+ pieces) within 15–20 working days after final approval.

   

  Customer Value Delivered: Ansix Tech maintains a 98% on-time delivery rate. Emergency rush services (e.g., 5-day prototype delivery) are available without compromising quality.

   

  Section 3: Injection Molding Process Control — Eliminating Customer Quality Anxiety

  3.1 Material Selection for Liquid Micrometer Aichi PPS Housing and PPS+PTFE Gears

  PPS (Polyphenylene Sulfide) Housing Material

   

  PPS offers exceptional thermal stability (up to 260°C continuous use), chemical resistance, and inherent flame retardancy (UL94 V-0). For Liquid Micrometer Aichi housings, Ansix Tech typically employs PPS+40%GF (40% glass fiber reinforced).

   

  Key Properties:

   

  Continuous use temperature: 240–260°C

   

  Flammability rating: UL94 V-0 without additives

   

  Chemical resistance: Excellent against oils, solvents, and automotive fluids

   

  Dimensional stability: Low coefficient of thermal expansion

   

  Processing temperature: 300–350°C; mold temperature 120–150°C required to develop full crystallinity

   

  PPS+PTFE Gear Material

   

  For gear applications requiring low friction and wear resistance, Ansix Tech utilizes PPS+PTFE compounds with glass or carbon fiber reinforcement. Typical formulations include:

   

  30% glass fiber + 15% PTFE: Low coefficient of friction for gear, bearing, and slide applications

   

  40% glass fiber + 15% PTFE: Higher strength with excellent wear resistance

   

  Carbon fiber + PTFE reinforced: Enhanced stiffness and thermal conductivity

   

  Material Shrinkage Characteristics:

   

  Linear mold shrinkage (flow direction): 0.2–0.4% for glass/PTFE-filled grades

   

  Linear mold shrinkage (transverse): Typically 0.4–0.8%

   

  Customer Value Delivered: Understanding and compensating for anisotropic shrinkage (different rates in flow vs. transverse directions) is critical for gear tooth geometry and housing sealing surfaces. Ansix Tech's MFA and mold design account for these variations to ensure first-shot dimensional accuracy, eliminating iterative mold modifications that add cost and delay.

   

  3.2 PPS Injection Molding Process Parameters

  Parameter PPS+40%GF Housing PPS+PTFE Gear

  Drying temperature 130–150°C 130–150°C

  Drying time 3–4 hours 3–4 hours

  Cylinder temperature 290–320°C 320–340°C

  Nozzle temperature 300–320°C 300–320°C

  Mold temperature 120–150°C >140°C

  Injection pressure 80–150 MPa 69–103 MPa

  Back pressure 30–70 MPa 30–70 MPa

  Customer Value Delivered: Ansix Tech's MES-locked parameters ensure every shot matches the validated process window. For critical gear applications, low injection speed, low holding pressure, and high mold temperature are recommended to maximize strength and minimize residual stress.

   

  3.3 Dimensional Stability Control

  Customer Value Delivered: Ansix Tech employs:

   

  Mold temperature zone control maintaining core and cavity temperature differentials within 2°C to reduce warpage

   

  Ultrasonic wall thickness sensors providing real-time feedback for automatic pressure compensation

   

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

   

  First-article inspection (FAI) with CMM and optical comparator for every batch

   

  Real-time SPC monitoring with key dimensions maintained at CPK ≥1.33

   

  For similar housing products, Ansix Tech has demonstrated critical hole spacing variation ≤0.02mm across three batches produced over one week—proving batch-to-batch consistency.

   

  3.4 Appearance Quality Standards

  Grade Application Specification Customer Value

  Class A Clear/transparent parts No bubbles, no flow marks Eliminates visual rejects

  Class B Plated/coated surfaces No gas marks, no splay Reduces surface preparation cost

  Class C High-gloss surfaces Surface roughness Ra ≤0.2μm Ready for assembly—no polishing

  For parts requiring painting or printing, Ansix Tech provides deformation compensation预留 (pre-calculated warp compensation in mold design), achieving print registration accuracy within ±0.1mm.

   

  3.5 Special Material Capabilities

  Ansix Tech has extensive production experience with a wide range of engineering plastics:

   

  PC/ABS, PC — General-purpose housings

   

  PPS+40%GF — High-temperature, chemical-resistant housings

   

  PEEK — Ultra-high-performance applications (450G, medical grades)

   

  PTFE/PFA — Fluoropolymer components

   

  PA6+GF30, PA66+GF30 — Structural automotive components

   

  PBT, PBT+GF30 — Electrical connectors

   

  PEI (Ultem®) — High-temperature transparent applications

   

  LCP — Thin-wall, high-flow electronic components

   

  LSR (Liquid Silicone Rubber) — Seals and overmolded components

   

  POM, PMMA, TPE/TPU, ABS, PP (including long-glass-fiber grades)

   

  Customer Value Delivered: With over 28 years of experience across 20+ material families, Ansix Tech provides material selection guidance that optimizes the balance between performance, cost, and manufacturability—reducing material-related risks before production begins.

   

  Section 4: Full-Process Service — Reducing Customer Management Cost

  4.1 Early Intervention (DFM Reports)

  Ansix Tech provides mold feasibility analysis reports before contract signing.

   

  Customer Value Delivered: The DFM report includes:

   

  Draft angle recommendations — Ensuring proper ejection without cosmetic damage

   

  Wall thickness optimization — Preventing sink marks and warpage

   

  Gate location recommendations — Minimizing visible gate marks and weld lines

   

  Ejector pin mark location allowances — Placing marks in non-critical areas

   

  Parting line optimization — Reducing flash and eliminating secondary deburring

   

  This early intervention prevents costly mold modifications after steel is cut—saving customers 15–30% of total tooling cost by identifying design-for-manufacturability issues before mold manufacturing begins.

   

  4.2 Trial Molding and Samples

  Ansix Tech provides T0 through T3 trial samples, with improvement reports for each round.

   

  Customer Value Delivered: The ability to quickly exchange inserts to validate different design approaches—without re-cutting the entire mold—enables rapid design iteration. This reduces development time and cost compared to full mold rework.

   

  4.3 Small-Batch Validation

  Formal mass production begins only after 100–500 shot trial production with statistical yield and CPK validation.

   

  Customer Value Delivered: This de-risks the production launch—ensuring the process is stable and capable before committing to full-scale production, preventing scrap and rework costs that typically arise during production ramp-up.

   

  4.4 Maintenance and Spare Parts

  Spare parts (ejector pins, cores) are delivered with the mold.

   

  Customer Value Delivered:

   

  Maintenance every 200,000 shots recommended

   

  Lifetime repair at cost (no profit markup on repairs)

   

  24-hour repair response for emergency situations

   

  3-year mold structure warranty (excluding normal wear of consumable parts)

   

  This comprehensive support ensures uninterrupted production and predictable maintenance costs over the mold's lifetime.

   

  Section 5: Differentiated Advantages — Direct Solutions to Common Industry Pain Points

  5.1 Mold Reliability and Unplanned Downtime

  Industry Complaint Ansix Tech Solution Customer Value

  "Molds require frequent repairs, disrupting orders" 2,000-shot wear test before delivery with wear report; 3-year structural warranty Predictable maintenance schedule; no surprise downtime

  "Mold repair takes too long" In-house electrode and EDM workshop; repairs completed within 24 hours Production resumes next day vs. 7–10 days with external suppliers

  "Replacement parts are expensive and slow" Spare parts (ejector pins, cores) included with mold delivery No third-party markup; immediate availability

  5.2 Flash Control and Secondary Operations

  Industry Complaint Ansix Tech Solution Customer Value

  "Excessive flash requires costly manual deburring" 0.005mm parting line matching precision; self-locking clamp force compensation Flash controlled within 0.03mm; eliminates manual deburring

  "Secondary operations add cost" Wire EDM enables 0.03mm features directly in mold 15–20% reduction in post-molding labor costs

  5.3 Dimensional Consistency

  Industry Complaint Ansix Tech Solution Customer Value

  "Dimensions vary from batch to batch" All-servo-electric machines with ±0.1% repeatability; MES-locked parameters 100,000th part matches the first

  "Warpage causes assembly issues" Zone-controlled cooling (2°C differential); ultrasonic wall thickness sensors Parts assemble without forcing or modification

  5.4 Cost Control

  Cost Driver Ansix Tech Solution Savings

  Material waste Hot runner systems; optimized gate design 15–25% material savings

  Energy consumption All-servo-electric machines; right-sized machine selection 20–30% energy reduction vs. hydraulic machines

  Scrap and rework 100% vision inspection; CPK ≥1.33 process control Scrap rates below 1.5% in production

  Post-molding operations Precision parting lines; in-mold micro-features 15–20% labor cost reduction

  Global logistics Four production bases (China and Vietnam) Reduced shipping costs; regional supply chain redundancy

  Section 6: Quality Assurance Framework

  6.1 Certifications and Standards

  Ansix Tech maintains comprehensive quality control systems and has successfully passed:

   

  ISO9001 — Quality management

   

  IATF16949 — Automotive industry quality

   

  ISO13485 — Medical device quality

   

  ISO14001 — Environmental management

   

  BSCI — Social compliance

   

  ISO Class 8 cleanroom and GMP-certified facilities compliant with US medical grade FDA 510K standards

   

  6.2 Quality Control Throughout Production

  Stage Activity Customer Value

  Raw material Verified PPS compounds from global suppliers; material certification reports Assured material properties; traceability

  Mold manufacturing Full dimensional report vs. CAD; CMM validation Mold accuracy verified before production

  First article FAI with CMM and optical comparator First parts match specifications

  Production Real-time SPC; CPK ≥1.33 Ongoing process capability

  Final inspection 100% vision inspection Zero defective parts shipped

  Packaging Cleanroom packaging; ESD protection where required Parts arrive ready for assembly

  Section 7: Cost Reduction Strategy — Delivering Competitive Advantage

  Ansix Tech's cost leadership is built on three pillars:

   

  7.1 Material Cost Optimization

  Volume purchasing power across 260 machines and four production bases

   

  Alternative material recommendations that balance performance and cost

   

  Hot runner systems that eliminate runner waste

   

  7.2 Process Efficiency Optimization

  MES-integrated smart manufacturing scheduling every step from material preparation → mold setup → automated molding → in-line inspection → packaging

   

  All-servo-electric machines reducing energy consumption by 20–30% vs. hydraulic

   

  Optimized cooling design reducing cycle time by 10–20%

   

  Multi-cavity tooling increasing output per machine hour

   

  7.3 Scale and Global Footprint

  260 injection molding machines across four production bases

   

  30 to 4,000 ton clamping force range covering all product sizes

   

  28 years of experience with proven production track record

   

  Conclusion

  For Ansix Tech, a mold is not just a block of steel—it is a revenue-generating asset for the customer. Every design decision—from steel selection to gate placement to cooling channel layout—is made with the customer's production efficiency, quality consistency, and total cost of ownership in mind.

   

  Key Customer Value Deliverables:

   

  Value Dimension Ansix Tech Commitment

  Quality ±0.005mm precision; CPK ≥1.33; 100% vision inspection

  Reliability 1-million-shot mold life for glass-filled PPS

  Speed 7–10 day samples; 15–20 day mass production; 24-hour repair response

  Cost 15–25% material savings; 15–20% labor reduction; 20–30% energy savings

  Risk reduction DFM before tooling; T0–T3 validation; small-batch qualification

  Compliance ISO9001, IATF16949, ISO13485, ISO14001, BSCI, FDA 510K

  Ansix Tech invites customers to experience the full-process DFM report walkthrough for an existing product—demonstrating firsthand how weld lines, gas traps, and shrinkage risks are identified and eliminated before a single gram of steel is cut. This is not just injection molding; it is engineered manufacturing partnership built on 28 years of proven excellence.

   

  Liquid Micrometer Aichi PPS Housing, PPS+PTFE Gears: A Comprehensive Industry Report

  Part I: Introduction to Liquid Micrometer Aichi PPS Housing and PPS+PTFE Gears

  1.1 Product Definition and Full Nomenclature

  The Liquid Micrometer Aichi PPS Housing, PPS+PTFE Gears represents a precision fluid measurement system manufactured by Aichi Tokei Denki Co., Ltd., a Japanese precision instrument manufacturer headquartered in Aichi Prefecture, Japan. This device is an advanced microflow sensor designed for accurate measurement of various liquids across industrial, commercial, and laboratory applications.

   

  Full English Terminology:

   

  Liquid Micrometer: A precision flow measurement instrument that utilizes positive displacement principles to quantify liquid flow rates with high accuracy. The device employs elliptic (oval) gears as the primary measuring mechanism.

   

  Aichi: Refers to Aichi Tokei Denki Co., Ltd., the Japanese manufacturer that develops and produces these precision flow sensors. The company is recognized globally for its expertise in flow measurement technology.

   

  PPS Housing: The external casing and structural body of the liquid micrometer manufactured from Polyphenylene Sulfide (PPS) . PPS is a high-performance engineering thermoplastic characterized by its semi-crystalline structure, exceptional thermal stability, and broad chemical resistance.

   

  PPS+PTFE Gears: The internal elliptic gear mechanism constructed from a composite material combining Polyphenylene Sulfide (PPS) with Polytetrafluoroethylene (PTFE) . This material combination creates a tribologically optimized compound that delivers low friction, excellent wear resistance, and superior chemical compatibility.

   

  1.2 The Aichi Tokei Denki Microflow Sensor Platform

  The Aichi OF-Z Microflow Sensor represents the flagship product utilizing this material configuration. This sensor is specifically designed for measuring oil (heavy oil, light oil, heating oil) and various other liquids with exceptional precision. Key features include:

   

  Measurement of microflow ranges with superior manufacturing technology

   

  Excellent performance in measuring pulsating flow

   

  Built-in amplifier magnetic sensor with noise resistance

   

  Pulse output via open collectors or voltage pulse

   

  Wide flow rate measurement range with high accuracy

   

  Simple structure employing elliptic gears as the measuring principle

   

  Capability to measure various liquids

   

  RoHS compliant

   

  The major materials exposed to liquid in this system include PPS for the case and rotor, with NBR or FKM O-rings. The OF-Z series offers flow rate ranges from 0.017 to 5 L/min depending on liquid viscosity, with accuracy of ±2% RS.

   

  1.3 Material Selection Rationale

  The selection of PPS for the housing and PPS+PTFE for the gears is not arbitrary but represents a carefully engineered material choice driven by the demanding operational requirements of precision liquid measurement. PPS offers an optimal balance of:

   

  Thermal Performance: Continuous service temperature up to 240°C and short-term resistance up to 270°C

   

  Chemical Resistance: No known solvents below 200°C

   

  Dimensional Stability: Minimal moisture absorption and low coefficient of thermal expansion

   

  Mechanical Strength: High stiffness, creep resistance, and strength

   

  The addition of PTFE to the gear material provides self-lubricating properties, significantly reducing friction and wear in the moving gear mechanism.

   

  Part II: Raw Material Characteristics and Technical Data Sheet (TDS)

  2.1 Polyphenylene Sulfide (PPS) – Housing Material

  Chemical Name: Polyphenylene Sulfide

  Abbreviation: PPS

  Chemical Structure: Semi-crystalline polymer with para-phenylene rings linked by sulfur atoms

   

  Key Properties of PPS:

   

  Property Value Test Method

  Density 1.35-1.70 g/cm³ ISO 1183 / ASTM D792

  Melting Point ~285°C

  Heat Deflection Temperature (1.8 MPa) 260-277°C ISO 75

  Tensile Strength 13500-16500 psi ASTM D638 / ISO 527

  Flexural Modulus 575000-14500 MPa ASTM D790 / ISO 178

  Hardness, Shore D 85 ASTM D2240

  Flammability Rating V-0 (UL 94)

  Dielectric Strength 540 V/mil

  Coefficient of Friction, Dynamic 0.40

  Performance Characteristics:

   

  PPS is a hard, brittle material with high crystallinity, excellent flame retardancy, good thermal stability, high mechanical strength, and superior electrical properties. It exhibits good fluidity, is easy to shape, and demonstrates almost no shrinkage pits during molding. PPS has good affinity with various inorganic fillers.

   

  Chemical Resistance: PPS offers the broadest resistance to chemicals of any advanced engineering plastic. It has no known solvents below 200°C and exhibits inertness to steam, strong bases, fuels, and acids. Minimal moisture absorption and a very low coefficient of linear thermal expansion make PPS ideally suited for precision tolerance components.

   

  2.2 PPS+PTFE Composite – Gear Material

  Full Name: Polyphenylene Sulfide + Polytetrafluoroethylene Composite

  Material Type: PPS/PTFE Alloy

   

  Representative Grades and Compositions:

   

  Grade Composition Key Features Application

  TEDUR® L 9401-1 40% Glass Fiber + 5% PTFE High stiffness, improved sliding/wear Bearings, sliding elements

  ES-SG301E43 30% Glass Fiber + PPS/PTFE Alloy Low coefficient of friction, low wear Gears, bearings, low-friction applications

  ES-SG401E65 40% Glass Fiber + PPS/PTFE Alloy High strength, low friction Gears, bearings, slides

  LNP LUBRICOMP OL009 45% PTFE Wear resistant Wear applications

  RTP 1300 TFE 30 SI 2 30% PTFE + 2% Silicone Low viscosity, excellent chemical resistance Housings, gears, bushings

  RTP 1305 TFE 15 30% Glass Fiber + 15% PTFE Wear resistant Housings, gears

  Key Properties of PPS+PTFE Composites:

   

  ES-SG301E43 Technical Data (30% GF PPS/PTFE Alloy):

   

  Property Value Test Method

  Density 1690 kg/m³ ISO 1183

  Tensile Strength 150 MPa ISO 527

  Elongation at Break 1.2% ISO 527

  Flexural Modulus 10 GPa ISO 178

  Flexural Strength 225 MPa ISO 178

  Charpy Impact Strength (V-notched) 9 kJ/m² ISO 179

  Melting Temperature 280°C ISO 11357

  Heat Deflection Temperature (1.8 MPa) 260°C ISO 75

  Flammability V-0 UL-94

  Mold Shrinkage (MD) 0.3% GB/T 15585

  Mold Shrinkage (TD) 0.7% GB/T 15585

  Water Absorption (23°C-sat) 0.03% ISO 62

  Dielectric Strength 16 KV/mm IEC 60243

  Volume Resistivity 2×10^15 Ω·cm IEC 60093

  TEDUR® L 9401-1 Technical Data (40% GF + 5% PTFE):

   

  Property Value Test Method

  Density 1700 kg/m³ ISO 1183

  Flexural Modulus 14000 MPa ISO 178

  Flexural Strength 245 MPa ISO 178

  Tensile Modulus 14500 MPa ISO 527

  Tensile Strength at Break 165 MPa ISO 527

  Tensile Elongation at Break 1.5% ISO 527

  Impact Strength (Charpy, 23°C) 38 kJ/m² ISO 179/1eU

  HDT/A (1.8 MPa) 277°C ISO 75-1/-2

  DSC Melt Point 280°C ISO 11357

  Coefficient of Sliding Friction µ 0.36 ASTM G 137

  Specific Wear Rate 0.82×10⁻⁶ mm³/Nm ASTM G 137

  Tribological Advantages of PPS+PTFE:

   

  The incorporation of PTFE into PPS significantly enhances the material's tribological properties. PTFE is known for its excellent thermal resistance, corrosion resistance, and self-lubricating properties. The addition of PPS significantly enhances the hardness of PTFE composites. At high strains, PPS/PTFE mixtures exhibit a compressive modulus two to three times as great as bronze-filled PTFE. Shore D hardness for PPS/PTFE compounds is usually 85 or higher compared to 60-75 for PTFE compounds.

   

  Processing Parameters for Injection Molding:

   

  Parameter Value

  Drying Temperature 130-150°C

  Drying Time 3-4 hours

  Melt Temperature 290-340°C

  Mold Temperature 120-165°C

  Injection Pressure 30-103 MPa

  Limit In-Cylinder Retention Time at 300°C Minimum 60 minutes

  Part III: Application Fields and Product Advantages

  3.1 Primary Application Domains

  The Liquid Micrometer Aichi PPS Housing with PPS+PTFE Gears finds applications across diverse industries where precise liquid flow measurement is critical.

   

  3.1.1 Industrial Flow Measurement

   

  Oval gear flow meters with PPS construction are widely used for continuous and intermittent measurement of liquid flow rates in pipelines. The positive displacement principle makes them particularly suitable for measuring high-viscosity media. Standard viscosity range typically covers 0.6 to 200 mPa·s, with specially designed meters extending to 1000 mPa·s.

   

  3.1.2 Fuel and Oil Measurement

   

  Aichi OF-Z sensors are specifically designed for measuring heavy oil, light oil, heating oil, and other petroleum products. Applications include:

   

  Kerosene burner combustion control for efficient fuel management

   

  Fuel consumption rate indication for internal combustion systems

   

  Remaining fuel monitoring

   

  Flow control for chemical feeder systems

   

  3.1.3 Chemical Processing

   

  PPS construction provides exceptional chemical resistance, making these meters suitable for:

   

  Corrosive liquid measurement (acids and alkalis)

   

  Chemical feeder system flow control

   

  Dosing and metering of polymers and corrosive chemicals

   

  3.1.4 Laboratory and Analytical Equipment

   

  PPS-based flow meters are ideal for laboratory applications requiring:

   

  High precision and accuracy

   

  Chemical compatibility with various reagents

   

  Compact form factor

   

  3.1.5 Liquid Cosmetic and Food Products

   

  The OF-Z sensor is capable of measuring flow of liquid cosmetic products, leveraging the material's inertness and cleanability.

   

  3.1.6 Automotive Applications

   

  PPS components are extensively used in automotive applications including:

   

  Vaporizers and distributor components

   

  Electronic and electrical components

   

  Sensor components

   

  Pump housings

   

  Thermostat housings and water pump caps

   

  3.2 Specific Products and Components

  3.2.1 OF-Z Microflow Sensor

   

  The OF-Z series is a flow sensor with elliptic gears that measures microflow with accuracy. Key specifications:

   

  Flow Rate Range: 0.017 to 5 L/min (viscosity dependent)

   

  Accuracy: ±2% RS

   

  Measurable Liquids: Cold/hot water, heating oil, light/heavy oil, mildly acidic/alkaline liquids

   

  Maximum Operating Pressure: 0.5 MPa

   

  Fluid Temperature Range: -10 to +70°C

   

  Output: Voltage pulse

   

  3.2.2 OF-WN/OF-WP Microstream Sensor

   

  This variant offers:

   

  Instantaneous flow rate and integrating flow volume display

   

  Built-in lithium batteries (no external power required)

   

  Revolving display unit

   

  Simplified structure with oval gears measuring principle

   

  Reset function for integrating flow volume indications

   

  Pulse output function option

   

  3.2.3 OM Series Chemical Flow Meters

   

  FLOMEC OM Series meters feature internal components constructed entirely from PPS (Ryton) and alumina ceramic. These meters are cost-effective alternatives to stainless steel meters when chemical resistance is critical.

   

  3.2.4 Masterflex GA-Series and GJ-Series Pump Heads

   

  These precision pump heads feature PPS gears and PTFE seals, providing durability, chemical resistance, and reliable performance for laboratory and process applications.

   

  3.3 Functional Advantages of PPS and PPS+PTFE in Liquid Micrometers

  3.3.1 Chemical Compatibility and Corrosion Resistance

   

  The broadest chemical resistance of any advanced engineering plastic enables PPS-based flow meters to handle aggressive fluids including acids, alkalis, and organic solvents. PPS components exhibit inertness to steam, strong bases, fuels, and acids. No known solvents below 200°C.

   

  3.3.2 Thermal Stability

   

  PPS maintains mechanical integrity across extreme temperature ranges:

   

  Continuous service: Up to 240°C

   

  Short-term: Up to 270°C

   

  Operating range: -65°C to 125°C for connectors

   

  Fluid temperature range: -10 to +70°C for OF-Z sensors

   

  3.3.3 Dimensional Stability and Precision

   

  PPS exhibits:

   

  Minimal moisture absorption (0.03% water absorption)

   

  Low coefficient of linear thermal expansion

   

  Excellent dimensional stability

   

  Almost no shrinkage pits during molding

   

  These properties ensure that precision-machined components maintain tight tolerances over their service life.

   

  3.3.4 Tribological Performance

   

  The PPS+PTFE gear material delivers exceptional wear and friction characteristics:

   

  Low coefficient of friction (0.14 static, 0.23 kinetic for some grades)

   

  Self-lubricating properties from PTFE

   

  Enhanced hardness compared to pure PTFE

   

  Compressive modulus 2-3 times greater than bronze-filled PTFE

   

  Low wear and friction consumption

   

  3.3.5 Mechanical Strength

   

  PPS provides:

   

  High mechanical strength and stiffness

   

  High creep resistance

   

  Excellent rigidity

   

  3.3.6 Electrical Properties

   

  PPS exhibits excellent electrical characteristics:

   

  Dielectric strength: 16 KV/mm

   

  Volume resistivity: 2×10^15 Ω·cm

   

  Low dissipation factor

   

  3.3.7 Flame Retardancy

   

  PPS is inherently flame retardant with UL 94 V-0 rating.

   

  3.3.8 Light Weight

   

  With density of 1.35-1.70 g/cm³, PPS is lighter than metals, contributing to reduced system weight.

   

  3.3.9 Cost-Effectiveness

   

  PPS provides a fraction of the cost of PEEK or polyimide while delivering comparable performance. PPS sits in a useful gap - better thermal and chemical performance than PA66, PBT, or PPA.

   

  Part IV: Ansix Tech - Specialized Manufacturer for Liquid Micrometer Components

  4.1 Company Overview

  Ansix Tech is a specialized manufacturer with over 29 years of experience in plastic mold and injection molding production. The company is dedicated to the research, development, design, manufacturing, sales, and service of plastic molds and products.

   

  Manufacturing Capabilities:

   

  260 injection molding machines across four production bases in China and Vietnam

   

  Clamping forces ranging from 30 tons to 2,800 tons

   

  Major machine brands: Fanuc, Sumitomo, Toshiba, Nissei, Engel (Japan), Arburg (Germany - primarily for liquid silicone injection molding)

   

  Fully electric servo presses with closed-loop process control

   

  Five-axis high-speed CNC machining centers achieving 0.002mm precision

   

  4.2 Ansix Tech's Expertise in PPS and PPS+PTFE Materials

  Ansix Tech has made strategic equipment investments specifically selected for high-performance engineering plastic molding. The company specializes in overcoming the complex challenges associated with PPS and PPS+PTFE material processing.

   

  Key Material Expertise:

   

  PPS+40%GF for high-temperature applications requiring extreme thermal stability

   

  PPS+65%GF for high-performance, heat-resistant, chemical-resistant applications

   

  PPS+PTFE compounds for tribological applications

   

  PEEK, PEI, LCP for high-performance electronics

   

  Overmolding capabilities combining PPS with metals (SUS316+Overmolding PPS)

   

  4.3 Custom Material Formulation and Development

  Ansix Tech undertakes custom material formulation projects for Liquid Micrometer Aichi PPS Housing and PPS+PTFE Gears, providing comprehensive material development and manufacturing services.

   

  Material Development Capabilities:

   

  Custom PPS/PTFE Compound Formulation: Ansix Tech works with material suppliers to develop proprietary PPS+PTFE compounds optimized for specific application requirements. This includes adjusting glass fiber content (from 30% to 65%), PTFE loading (5% to 45%), and incorporating additional additives such as carbon fiber, graphite, or silicone for enhanced performance.

   

  Material Selection Consultation: With deep understanding of PPS material behavior, processing windows, and grade characteristics, Ansix Tech guides customers in selecting the optimal material formulation for their specific application.

   

  Performance Optimization: Custom formulations can be tailored to achieve specific property targets including:

   

  Reduced coefficient of friction

   

  Enhanced wear resistance

   

  Improved flowability for complex geometries

   

  Optimized thermal and chemical resistance

   

  4.4 Value Proposition to Customers

  4.4.1 Solving Complex Molding Challenges

   

  PPS injection molding presents unique challenges that require specialized expertise. PPS defects are not generic molding defects, and PPS tooling is not generic engineering-plastic tooling. Ansix Tech's 29+ years of experience enables the company to address:

   

  Filling Defects: High-thermal-conductivity PPS often causes filling defects due to rapid solidification during the filling process

   

  Crystallization Control: Low mold temperature leads to incomplete crystallization, causing recrystallization during baking, glass fiber exposure, surface pitting, and gate breakage issues

   

  Shrinkage Anisotropy: Glass-filled PPS exhibits anisotropic shrinkage that must be accounted for in mold design

   

  Warpage Control: Mineral-and-glass blends are used when anisotropic fiber shrinkage warps parts beyond specification

   

  4.4.2 Cost Reduction

   

  Ansix Tech delivers significant cost savings through:

   

  Material Cost Optimization: By selecting the optimal PPS/PTFE grade and filler content for each application, Ansix Tech ensures customers pay only for the performance they need. For tribological applications, PTFE or graphite-filled grades provide the necessary wear resistance without over-specifying.

   

  Process Efficiency: Optimized injection molding parameters including melt temperature (290-340°C), mold temperature (120-165°C), and injection pressure (30-103 MPa) are fine-tuned to maximize cycle efficiency while maintaining part quality.

   

  Tooling Design for High-Volume Production: Multi-cavity molds (64, 96, or even 128 cavities) maximize output per machine cycle, significantly reducing per-part costs.

   

  Reduced Scrap Rates: Through precise process control and DFM analysis, Ansix Tech minimizes rejections and material waste.

   

  Mold Life Optimization: For glass-filled PPS, Ansix Tech guarantees 1-million-shot mold life, reducing tooling replacement costs.

   

  4.4.3 Capacity and Delivery Assurance

   

  260 injection molding machines ensure ample production capacity

   

  Four production bases provide geographic redundancy and supply chain resilience

   

  Industry 4.0 intelligent manufacturing with temperature-controlled production areas

   

  24/7 operation of automatic pickup, calibration, processing, cleaning, and CMM inspection

   

  4.4.4 Quality Validation and Assurance

   

  Ansix Tech implements comprehensive quality validation processes:

   

  DFM (Design for Manufacturing) analysis

   

  Mold flow analysis (FEA) to predict and mitigate potential issues before steel is cut

   

  Sample inspection reports

   

  CMM (Coordinate Measuring Machine) reports

   

  Material confirmation

   

  Trial records

   

  Mold maintenance documentation

   

  4.5 Design and Manufacturing Process

  4.5.1 Mold Flow Analysis and DFM

   

  Early engagement with molders and toolmakers for DFM analysis is crucial for successful PPS injection molding. Ansix Tech utilizes Moldflow analysis (FEA) to predict and mitigate potential issues before steel is cut. This includes:

   

  De-risking tooling

   

  Reducing warp and shrinkage

   

  Optimizing cooling paths

   

  Resin selection for heat, chemical, and wear resistance

   

  4.5.2 Mold Design Priorities

   

  Based on comprehensive engineering references for PPS material behavior, Ansix Tech's mold design addresses:

   

  Gate and Runner System:

   

  Optimized gate position and number to ensure smooth resin flow throughout the cavity

   

  Proper runner thickness to prevent flow issues

   

  Design consideration for GF shrinkage anisotropy

   

  Cooling System:

   

  Optimized cooling paths to control crystallization behavior

   

  Mold temperature control between 120-165°C

   

  Uniform cooling to minimize warpage

   

  Ejection System:

   

  Robust ejection design for complex geometries

   

  Consideration for PPS brittleness

   

  4.5.3 Mold Manufacturing

   

  Core/Cavity materials: Powder metallurgy steel M340, 9Cr18 for high-wear applications

   

  Hardened tooling for glass-filled PPS

   

  Five-axis high-speed CNC machining achieving 0.002mm precision

   

  4.5.4 Injection Molding Process

   

  Processing Guidelines for PPS/PTFE Compounds:

   

  Parameter Value

  Pre-Drying 130-150°C for 3-4 hours in desiccant dryer

  Melt Temperature 290-340°C

  Mold Temperature 120-165°C

  Injection Pressure 30-103 MPa

  Back Pressure 0.2-0.3 MPa

  Screw Speed 30-60 rpm

  Key Processing Challenges:

   

  Moisture Control: PPS must be thoroughly dried; moisture causes surface defects and property degradation

   

  Thermal Degradation: In-cylinder retention time at 300°C must be limited to minimum 60 minutes

   

  Rapid Solidification: High thermal conductivity causes rapid cooling during filling

   

  Crystallization Control: Mold temperature critically influences crystalline structure and material properties

   

  4.5.5 Quality Control

   

  CMM inspection for dimensional verification

   

  Automated inspection systems

   

  Process monitoring with closed-loop control

   

  Statistical process control

   

  4.5.6 Packaging and Delivery

   

  Customized packaging solutions

   

  Rapid delivery through optimized logistics

   

  Four production bases ensuring supply chain reliability

   

  4.6 Industry Experience and Reliability

  Ansix Tech's 29+ years of manufacturing experience encompasses:

   

  Medical injection pump component molds

   

  High-cavity molds for high-volume production (64, 96, 128 cavities)

   

  PPS card inserts with precise dimensional stability

   

  PPS+GF40 cell holders

   

  Medical filter overmolding (SUS316+Overmolding PPS)

   

  Hot-plate welding for PPS+GF40 electronic water pumps

   

  Centrifugal impellers in PPS+40%GF

   

  4.7 Material Selection Guidance

  Ansix Tech assists customers in selecting the appropriate PPS/PTFE grade based on the specific failure mode being avoided:

   

  Application Requirement Recommended Grade

  Mechanical/thermal problems Reinforced grades (GF-filled)

  Chemical/electrical problems Unfilled grades

  Wear/friction problems Tribological grades (PTFE/graphite-filled)

  Chemical handling/isolation Unfilled grades

  Bearings and sliding elements TEDUR L 9401-1 (40% GF + 5% PTFE)

  Gears, bearings, slides ES-SG301E43 or ES-SG401E65

  Wear applications LNP LUBRICOMP OL009 (45% PTFE)

  Housings, gears, bushings RTP 1300 TFE 30 SI 2

  Part V: Conclusion

  The Liquid Micrometer Aichi PPS Housing with PPS+PTFE Gears represents a sophisticated integration of advanced polymer materials into precision fluid measurement technology. The combination of PPS for the housing and PPS+PTFE for the gears delivers an optimal balance of chemical resistance, thermal stability, dimensional precision, tribological performance, and cost-effectiveness.

   

  PPS Housing provides exceptional chemical resistance, thermal stability up to 240°C continuous service, excellent dimensional stability with minimal moisture absorption, and inherent flame retardancy.

   

  PPS+PTFE Gears leverage the self-lubricating properties of PTFE combined with the mechanical strength and hardness of PPS, delivering low coefficient of friction, excellent wear resistance, and enhanced durability.

   

  Ansix Tech, with over 29 years of specialized manufacturing experience, provides comprehensive solutions for these demanding components. From custom material formulation and DFM analysis to precision mold manufacturing and optimized injection molding, Ansix Tech addresses the complex challenges inherent in PPS processing. The company's extensive manufacturing infrastructure - 260 injection molding machines across four production bases - ensures reliable capacity and delivery.

   

  Through custom material development, process optimization, and rigorous quality validation, Ansix Tech delivers significant value to customers including cost reduction, quality assurance, and supply chain reliability. The company's expertise in overcoming PPS-specific molding challenges - crystallinity control, shrinkage management, and thermal degradation prevention - positions Ansix Tech as a preferred partner for Liquid Micrometer Aichi PPS Housing and PPS+PTFE Gears manufacturing.

   

  As industries continue to demand higher precision, greater chemical resistance, and improved reliability from fluid measurement systems, the combination of advanced PPS/PTFE materials and specialized manufacturing expertise will remain essential. Ansix Tech's commitment to innovation, quality, and customer value ensures it will continue to play a vital role in this critical supply chain, delivering components that meet the most demanding performance requirements while optimizing total cost of ownership.

   

   

  Ansix Tech Co Ltd

  If you have any plans related to Liquid micrometer  Aichi PPS housing, PPS+PTFE gears  , 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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