Description
This sunroof frame is made from high-quality plastic material, crafted using vacuum-forming technology. The product design focuses on structural strength, with a smooth surface and impact resistance, providing reliable support and protection for the sunroof system. It is suitable for large vehicles or trucks, ensuring durability and stability even in harsh environments. The overall design is simple and practical, meeting the modification needs for sunroofs on various types of vehicles.
Material Recommendation About Custom Vacuum-Formed Plastic Sunroof Frame
| plastic material | advantage | industry example |
| ABS (Acrylonitrile Butadiene Styrene) | ABS has very good mechanical properties, dimensional stability, processing ability, chemical resistance, and a high-quality appearance | It has been widely used in manufacturing machinery, electronic components, electrical and home appliances, auto parts, medical products, food and water contact materials, construction materials, toys and sporting goods, and cosmetics containers. |
| ASA | ASA is a copolymerization of styrene, acrylonitrile, and acrylic rubber. Technically, ASA not only maintained the main characteristics of the ABS, but it also combines the weather resistance advantage of acrylic to extend the product application for outdoor purposes. weather resistance durability, color stability, and good PC/PVC capability | Can be applied to automotive parts, construction parts, outdoor sporting goods, gardening parts, outdoor antenna parts, electronic and electrical products, toiletries, etc. In addition, ASA also reduces the secondary coating and electroplating processing costs, allowing its products to have cost-reducing and environmentally friendly features. |
| PS(Polystyrene) | PS resin is a solid polymer formed by heat polymerization of styrene. High Impact Polystyrene (HIPS) is composed of SM and butadiene (BD). HIPS is high-impact resistant and non-transparent | suitable for home appliances, food and water contact materials, toys, construction materials, and especially appliance housings due to its excellent processability |
| PMMA | PMMA resin is a polymer mainly composed of methacrylate (MMA). It features high cleanliness, crystal-clear transparency, and high gloss, earning it the nickname Plastic Queen for its excellent appearance. It also delivers stable physical, chemical, optical, and electrical properties. | widely used in the application of electronic panels, mechanical parts, surfaces of watches and clocks, vehicle lights, telecommunication equipment, insulation parts, sunglasses, food and water contact materials, cosmetics containers, and toys |
| Polycarbonate | This resin offers glass-like transparency, high heat resistance, ultra-high impact resistance, and dimensional stability, making it suitable for a wide range of applications. It is also compatible with other materials such as ABS and PET, creating diverse alloy products | suitable for ethylene oxide and gamma-ray disinfection, and can be applied in medical equipment. This material is also suitable for all 3C products, precision machinery, instrument products, automotive parts, sporting goods, sanitary hygiene products, and food and water contact materials. |
| Polycarbonate/A BS | Balances the properties of polycarbonate (PC) and acryloni-trile-butadiene-styrene copolymer (ABS). The PC component provides high heat resistance, high impact resistance, non-halogen flame retardancy, and high rigidity and tensile strength properties. The ABS component gives better processability, higher impact strength in low-temperature environments, and the ability to be electroplated, dimensional stability, and a high-quality appearance | This material effectively reduces the visible signs of injection, provides a wider range of injection conditions, and improves the maintenance rate for related equipment. Suitable applications range across transportation, networking, 3C electronics products, TV sets, home appliances, toys, and sporting goods. |
| PETG (polyethylene terephthalate) | Very easy to process, high clarity -good for transparent parts， UV protection, high impact, Excellent chemical resistance | it is widely used in indoor and outdoor signage, storage shelves, vending machine panels, furniture, construction, and mechanical baffles. |
| PE | heat resistant, and cold resistance, High impact, chemical stability | it is widely used in Arena boards, bulletproof boards, bottle caps, chemical corrosion-resistant pipeline systems, car fuel tanks, food storage containers, safety helmet |
DitaiPlastic Vacuum Forming Factory
Vacuum Forming Main Steps
1. Customer provides the 3D drawings or product samples.
After the customer provides the 3D drawing, our salesperson will use his rich experience to provide customers with improvement suggestions, striving to make the final product more in line with customer needs. If the customer is unable to provide a 3D drawing, we also provide the option of receiving a sample. We will transcribe and scan the sample to make a 3D drawing. This is the first important step in the vacuum forming process. Whether the customer provides a 3D drawing or a sample, we are committed to providing customers with personalized services, striving to ensure the quality and perfect match of the final product.
2. Giving you suggestions and related quotations.
According to different applications of the products. The material we matched for you during vacuum forming is also different. That is great if you have your own choice of raw material, or we can match the most suitable raw material for your reference. Here is the introduction of the different plastic raw materials. Once we get your drawings, we will evaluate this and give your our best suggestion and quotation.
3. Mold Production.
In vacuum forming, we use aluminum molds extensively because they are strong and durable, have excellent thermal conductivity, and can produce high-quality parts. After receiving the customer’s product design drawings, our mold engineers will first confirm the required materials. Then, based on the shrinkage rate of the material and the customer’s design drawings, the mold engineers will design the corresponding 3D mold drawings. In this process, we will fully consider the surface effect, actual assembly and use environment of the product. For example, for transparent products or products with high surface effect requirements, we usually use block aluminum molds; for solid color products and products with textured surfaces, we choose cast aluminum molds; and for complex part geometries, we use slider aluminum molds. In addition, we also provide textured acid-etched molds, also known as texture molds or pattern molds, that meet all international standard texture codes to ensure that the mold design meets customer needs as much as possible. Our company has advanced mold CNC equipment, which can effectively control quality, time and cost, and strive to provide customers with efficient and reliable mold manufacturing services. After the mold is CNC machined, it will be polished and vacuum drilled. During the plastic molding stage, these molds are seamlessly integrated into our vacuum forming machines. As the plastic sheet melts, the mold rises to achieve complete bonding and any trapped air is removed with the help of a vacuum pump, ensuring the final product is as flawless as possible. After cooling, the product is demoulded. We mainly use 6061 aluminum to make aluminum molds. Depending on your specific requirements, we also provide mold warranty services. If the mold is worn, damaged or deformed, we will also provide a replacement service.
4. Raw material extrusion.
We have two self-owned sheet machines, using raw material pellets imported from Sinopec or Chimei, which is our guarantee of quality. The extrusion principle of the sheet is to melt the pellets by heating and extruding them. We can produce sheets with a thickness of 0.1-12mm and a maximum width of 2 meters. The sheets commonly used for blistering include ABS, ASA, HIPS (PS), HDPE (PE), PP, PMMA, PC, PETG, etc. We provide single-layer sheets and composite sheets (such as ASA+ABS or ABS+PMMA) to meet different cost, quality and delivery requirements. In addition, customers can also customize different colors, including all colors on the Pantone color card. At the same time, we can customize the performance of the sheet according to needs, such as UV resistance, fire resistance, corrosion resistance, high temperature resistance and high impact resistance. These raw materials can meet the various needs of customers for color and performance, and you can also choose different textures of plastic surfaces (single or double sides). We provide a variety of surface texture options, such as frosted and electronic texture, and if there is no ready-made, we can also customize the texture roller according to your requirements. The sheet can even be attached with leather texture. This is the second key step in the vacuum forming process and one of the two necessary raw materials for blister forming. We provide customers with a variety of sheet options and strive to ensure product quality and reliability through advanced production processes.
5. Vacuum forming Production Steps.
In the vacuum forming step, our production staff has more than 30 years of professional experience and has rich expertise and unique insights in processing various types and thicknesses of sheets. Our company is equipped with 17 large professional vacuum forming machines, which can turn your ideas and designs into real products according to design requirements. Before vacuum forming, we will use a mold temperature gun to detect the temperature of the mold to ensure that the temperature of the mold can make the product better. At the same time, we will adjust the temperature most suitable for vacuum forming of the product based on our rich experience and the characteristics of the sheet material to ensure the smooth progress of the forming process. In order to ensure the accuracy of size and thickness, we usually adjust the machine and proof several times. Before vacuum forming, an air gun is also used to blow away the dust attached to the surface of the sheet. After vacuum forming, we will use an ultrasonic thickness gauge to detect the thickness of each position of the product, striving to meet the design requirements. According to the test results, if defects or size mismatch are found, we will adjust the vacuum forming parameters appropriately to further optimize the quality and performance of the product. During the forming process, we will ensure uniform stretching by blowing bubbles, and the upper mold will also be used for some special structures. For designs with undercut structures, we provide two solutions: one is to modify the mold (cylinder molds are expensive), and the other is to use cylinder molds. The protruding part of the cylinder mold will pop out when needed, and shrink after molding and cooling, thereby meeting the requirements of the product structure.
6. CNC Production.
After the extrusion, molding and vacuum forming process of the plastic sheet, the next step is CNC cutting. After molding, our CNC engineers will convert the 3D file into a CNC-specific file, program the data, and then remove the excess material from the outside. The shape, drilling and chamfering of the product are all completed in this step. In the CNC cutting step, our company has thirteen three-axis CNCs and fifteen five-axis CNC equipment. The three-axis CNC is mainly used to process flat or simple curved workpieces, with stable processing characteristics; while the five-axis CNC is equipped with a 360° high-speed robotic arm, which can quickly and accurately cut the molded products to meet various production needs. We use a vacuum pump or magnet to fix the product on a fixture with the same shape as the product for CNC cutting to ensure the accuracy and stability of the cutting. Usually, our CNC engineers will input the program, and the machine will automatically operate to cut the shape of the product. In order to maintain the accuracy of the cut product, taking the five-axis machine as an example, we usually make a fiberglass or wooden mold, the surface shape of which fits the shape of the product, and vacuum drill holes on the surface of the mold and embed magnets. During the cutting process, the vacuum pump will extract the air between the mold and the product through the air holes above the mold, and the magnet will fit on the surface of the product. The suction of the magnet and the vacuum pump will firmly fix the product on the mold, thus helping to ensure that the size of the cut product is relatively accurate. We also provide acrylic/PMMA laser cutting machine services. Compared with CNC cutting machines, the advantages of laser cutting machines are that there are no burrs in the cutting area, the cutting speed is fast and accurate, but laser cutting is mainly used for the processing of flat materials.
7. Polish, Burring on the finished products.
Improve product quality: The presence of burrs will directly affect the appearance quality, assembly accuracy and performance of the product. Removing burrs can make the product surface smoother and flatter, thereby improving the overall quality. Ensure safety: Burrs may scratch operators or users, and even cause failures in some precision equipment. Therefore, removing burrs is an important measure to ensure production safety and product safety. Meet customer needs: Many customers have strict requirements on the appearance and accuracy of products, and removing burrs is a key step to meet these requirements.
8. Extra treatment: gluing, painting, and silk-screen.
Some products also need glue, paint, or silk-screen treatment. These can improve the whole product’s beauty and appearance. and DITAI also has a related department for this treatment.
9. Quality testing.
Once the products are finished, we have well-trained engineers or our sales will test the product’s size, color, and whole quality to ensure the product’s quality arrives at our customer’s hand satisfying.
10. Package and delivery.
According to the different product requests, we will match different packages for these. Like carton boxes, wood boxes, pallets, etc…If you wish, we also can arrange the shipment for you to save time for this order.
Future trends of the industry
Personalized customization: Ditai vacuum forming has many years of experience in vacuum forming and auto parts product design and manufacturing, and has unique insights into the design of each auto parts product. We will follow up on orders and discuss needs with every customer who makes a transaction, and discuss their needs with customers. Customers conduct professional integration discussions to meet their customized needs for auto parts products. Green production: ESG, sustainable development, and environmental protection awareness continue to increase. Green development has become an important direction for manufacturing innovation. In this regard, Ditai is also constantly optimizing the production process and manufacturing technology, and increasing the treatment of carbon emissions, energy consumption, etc. Invest heavily and adopt green manufacturing concepts and technologies to achiev sustainable development of the enterprise. Cross-border integration: The integrated development of manufacturing and other industries is already a global development trend. Ditai also attaches great importance to this aspect. Ditai Blister continues to participate in national development and cooperation with international brands to provide customers with better products.
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