In the development of traditional sanitary ware, about 40% of the time is wasted on "repeated proofing" caused by wrong estimation of shrinkage rate or improper mold structure. The core logic of Sunlets is to use the "process front" strategy,Solve 90% of manufacturing risks before mold manufacturing.
Analysis of key nodes: refined timeline We decompose a complete high-end OEM development cycle (average 45-60 days) into the following four core milestones:
Digital audit and manufacturability design verification (days 1-7)
Ensure that the design draft has "mass production genes".
We not only calculate the comprehensive shrinkage rate of 11.5-12.5 by CAD, but also introduce fluid dynamics simulation to predict the filling behavior of mud in high-pressure grouting environment.
Through the preset "structure Library", we can quickly identify the sharp corners or weak wall thickness that are easy to cause dry cracking,Eliminate rework risk in the digital phase.
Precision mold development and first sample (T1) output (days 8-25)
From digital models to physical objects.
Sunlets adopts five-axis CNC direct machining working die. Unlike plaster molds, our high-pressure resin molds can maintain extremely high consistency after one molding.Compared with the traditional process, CNC molding technology can improve the precision of the mold to ± 0.2mm, laying the foundation for the later automatic glazing.
Performance test and formula adaptation (26-40 days)
Achieve product densification and functional compliance.
Adjust the ratio of sizing agent and plasticizer for new products.We use a 128 cubic meter shuttle kiln for small batch trials and monitor the heating curve in real time to ensure that the sample does not produce Glaze defects when it is first fired.
Certification Passed and Mass Production Handover (Days 41-60)
Get CUPC/CE certification and transfer to fully automated production.
True efficiency comes from "sample production consistency". Since the combined high-pressure grouting machine is used in the sample stage, the yield of mass production conversion can usually reach more than 97% in the first month.
In the mold manufacturing at the same time, complete the packaging design and logistics program evaluation.
Data closed loop: the 3D scan data of each version of the sample will be fed back to the research and development library,Ensure more accurate shrinkage compensation for the next development.