Introduction: Moving from" trial and error "to" verification "
In the sanitary ceramics industry, new product development (NPD) is a high-investment, high-risk game. According to incomplete industry statistics, the failure rate from conceptual design to successful mass production in traditional ceramic research and development is often as high as 30%-40%,The reasons are usually concentrated in the firing cracking, the function is not up to standard or the mold life is too short. In the development of high-end bathroom products, the biggest risk is not that the design is not beautiful enough, but that the design cannot be economically and stably produced. Sunlets (Sunlets) believes that the core of reducing R & D risk lies in the process front-that is, before the raw materials are put into the production line,Through digital simulation and scientific pulping, all potential failure points are predicted and eliminated.
First, physical risk prevention and control: use simulation to avoid design defects
Ceramic materials in the drying and firing process of nonlinear shrinkage is the main source of risk.
For complex types such as toilet without ring hole or large-size basin,We use finite element analysis to simulate the residual stress during cooling.
Experiments have shown that by adding a 0.5-1.0mm transition fillet to the internal cavity, the risk of cracking caused by thermal stress can be reduced by 22%.
Fluid filling simulation: Before manufacturing the high pressure resin mold, simulate the mud at Filling trajectory under 1.2 MPa pressure. According to the relevant research of ScienceDirect, the precise flow channel design can effectively avoid the "cavity" or "cold joint mark" caused by local poor exhaust ".
Second, material risk prevention and control: the precise ratio of coagulant and plasticizer
improper formula is the invisible killer leading to batch defective products.
Slurry stability test: During the development phase, we will perform a 48-hour thixotropy follow-up test on the slurry. Ensure that the slurry does not segregate in a high pressure environment after the addition of the specific decoagulant.
Green strength guarantee: through the introduction of polymer plasticizer, improve the bending strength of unfired green body.This significantly reduces the risk of breakage during handling and automated glazing, which, according to our internal data, can increase the overall yield by 5-8 percentage points.
Process risk prevention and control: phased verification and sample review mechanism
3D printing fast sample: provide 1:1 physical sample before mold development,For customers to verify the installation structure and ergonomics.
Small batch Pressure Test: adhere to the high pressure grouting equipment proofing, rather than plaster mold proofing.
Core logic: Only when the proofing environment is highly consistent with the mass production environment can the authenticity of the sample performance be ensured.