Case Studies

Taifu bakelite vertical machines produce a wide range of phenolic parts: tableware, handwheels, handles, knobs and grips, cookware and wok handles, pressure-cooker handles and lugs, switches, oven parts, terminals, meter parts and housings, and other functional parts used at high temperatures. Clamping forces range from 35 to 500 tons with shot weights from 60 g to 3,000 g. The molding principle is the same as for standard plastics, but because bakelite is a thermoset, the machine needs a dedicated barrel and screw assembly. The material is melted in the barrel, injected into the cavity and then cured by heat in a dedicated bakelite mold. Available series TFV4 — standard vertical machine, vertical clamping and vertical injection TFVS — single sliding table for easy insert loading and unloading TFVSD — double sliding table, for higher productivity and better protection of molds and operators TFVR — rotary table, from two stations (2R) to multi-station (5R), for single-operator or automated production

Taifu high-speed vertical machines are designed for ultra-thin-wall parts. They offer a large mold mounting area, injection speeds up to 500 mm/s and clamping forces from 35 to 500 tons, with vertical clamping and vertical injection. Versions Fixed table: fixed lower mold, moving upper mold. Sliding table: one upper and one lower mold; the lower mold slides in and out, so the operator's hands stay outside the clamping area. Rotary table: one upper mold and two or more lower molds, indexing 180°; can be fully automated to save labor. All three versions come with safety doors and light curtains, low-pressure mold protection and overload protection. Bosch Rexroth servo valves are optional, giving closed-loop injection control and high shot accuracy for thin-wall parts. Applications Connectors for new-energy vehicles and mobile phones, card trays, SIM and SD cards, contactless IC cards, fiber-optic connectors, reader-head holders, IC sockets and trays, small switches, waterproof plugs, eyewear nose pads, buttons, tags, overmolded shoe studs, and parts for clocks and cameras.

LSR injection machines produce silicone parts such as medical products (infusion tubes, breathing masks), baby products (nipples, teethers), food-storage lids and diving products. LSR shares the properties of conventional silicone rubber — heat resistance, electrical insulation and resistance to radiation and electrical discharge — and is available in general-purpose, high-strength, transparent and flame-retardant grades. The two liquid components, A and B, are loaded into the machine and mixed and molded fully automatically, simplifying the process and shortening cycle times. Hardness ranges from 10° to 70°. Typical products LSR keypads and baby bottle nipples — classic high-volume LSR parts. Although LSR costs more than solid silicone, high volumes and virtually no waste keep overall costs down, and LSR nipples are more transparent. Printer rollers and seals that require low compression set and good elasticity Products in direct contact with the body, such as masks, laryngeal masks and medical products Cable accessories, watch straps, phone cases, baby bottles, bowls, nose pads, earplugs, diving masks, tubing and automotive parts

As vehicle lightweighting advances with electric and new-energy vehicles, overmolding on vertical machines is playing a bigger role in automotive manufacturing. Typical automotive overmolded parts Automotive glass encapsulation, filter screens, brake lever overmolding, seals, connectors and key overmolding can all be produced by two-shot or insert molding on sliding table or rotary vertical machines. Process requirements The process covers plasticizing, injection and molding. Good plasticizing is the precondition for part quality; injection must provide enough pressure and speed. Because average cavity pressure is typically 20–45 MPa, sufficient clamping force is essential — the injection and clamping units are the key components of the machine. Typical cycle on a vertical machine Load insert → screw forward → inject → hold → recover → decompress → cool → open mold → eject → retract ejector → remove part. Taifu machines for this sector include two-station rotary machines, cable-molding machines, LSR machines, high-speed machines, multi-color/multi-material machines, automatic strip-feed machines, energy-saving machines and rotary machines for new-energy battery cover plates.

Challenge A customer in Huizhou needed machines for ultra-thin molded parts, delivered on a fixed schedule. Machine Taifu high-speed vertical molding machines with accumulator-assisted injection. Solution The machines offer high-speed, high-pressure injection with an accumulator, reaching a maximum injection speed of 380 mm/s, and are suited to parts with walls below 0.2 mm. Parallel multi-circuit movements overlap ejection and screw recovery with mold opening — a cycle of about 10 seconds on a standard machine can be cut to about 6 seconds. Imported hydraulic components and controls, and automatic fault display, support stable running and easy maintenance. Result All six machines were shipped to the customer on 6 April 2020, on schedule.

Challenge Automotive lamps must meet safety regulations, blend with the vehicle's styling and meet aerodynamic requirements — making multi-color lamp components demanding to mold. Machine Taifu two-color injection molding machine. Solution The Taifu team worked with the customer to develop the multi-color molding process for the lamp components, injecting two different materials into one mold so that each part is formed from two materials or colors. Result The project was completed successfully and was followed by further two-color machine orders from customers in China and abroad, particularly for automotive parts.

Challenge A phone-component manufacturer's project manager was looking for an experienced vertical machine manufacturer able to deliver a batch of rotary machines on time. Machine Taifu vertical rotary table injection molding machines (2018). Solution After finding Taifu online and reviewing its more than ten years of machine-building experience, the customer signed the contract and production was scheduled immediately. Result The batch of rotary machines was delivered to the customer on time, with quality maintained.

Challenge A leading electronics contract manufacturer was looking for a supplier with the production capacity and installation expertise to deliver a batch of C-frame vertical machines. Machine Taifu C-frame vertical injection molding machines (2017). Result After delivery, the customer reported that it was satisfied with the machines and would continue to work with Taifu.

Challenge A global electrical equipment manufacturer places strong emphasis on product quality and needed a supplier with documented quality control. Machine Taifu high-speed vertical rotary table machines (2016). Solution Core components are imported from Germany, Japan and Italy. Taifu engineers also provide free operation training, commissioning, maintenance and servicing. Result the customer placed the order and described the cooperation as saving it time, effort and cost.