In the development of sanitary ceramics, the most common failure stems from the designer's insufficient estimation of material properties (such as drying shrinkage). Sunlets Sanitaryware , as an enterprise integrating equipment research and development and ceramic production in China,We have reduced the development cycle from 4-6 months to 45-60 days through a digital closed-loop development process.
Phase 1: Digital Prototyping and Shrinkage Compensation
All high-end OEM collaborations begin with an in-depth review of the CAD model.
Three-dimensional compensation design: Sanitary ceramics will produce a linear shrinkage of about 10%-12% during the drying and firing stages.We use professional simulation software to model the characteristics of the slurry and predict the stress distribution of complex geometries (such as a toilet without a ring hole) at different wall thicknesses.
Manufacturing-oriented design evaluation: Our team of more than 40 engineers will evaluate whether the product is suitable for high-pressure grouting molding, by optimizing the internal structure,Reduces demoulding resistance.
Stage 2: Precision mold development and high-pressure adaptation
Unlike traditional gypsum molds, high-pressure grouting requires high-strength porous resin molds.
CNC and 3D Scanning: we use the five-axis CNC center to directly process the main mold, and use 3D scanner for comparison,Ensure that the mold accuracy is controlled within ± 0.2mm. This ensures consistency in the later production of multiple molds in parallel.
Pressure distribution test: For large-size products (such as shower room base, wash basin), we will carry out mold runner test to ensure that the slurry under the synergistic effect of decoagulant and plasticizer can be in 1.0 MPa pressure under uniform wall.
Stage 3: Slurry formulation tuning and first sample manufacturing
In this stage, we convert the physical properties required by our customers into chemical formulations.
Rheological matching: according to different types of devices, adjust the proportion of decoagulant to ensure that the solid content of mud is between 68% and 72%.
Test firing monitoring: The first sample is fired in a 96-meter tunnel kiln to ensure that the product is fully densified and free of Glaze defects by monitoring the real-time heating curve.
Phase 4: Verification, Certification and Mass Production
Performance Test: Water Flushing test, load test and surface anti-fouling test are carried out in strict accordance with international standards (such as American CUPC, European CE or Japanese JIS).According to the global market, the compliance requirements for sanitary ceramics are increasing.
Automated mass production: After confirmation, the product is transferred to high-pressure grouting equipment for 24-hour automated production, which significantly reduces manual errors.