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  • EV Charging Connector Overmolding Production Solution with 160T Single Sliding Table Vertical Injection Molding Machine

    Case Introduction
    This customer specializes in manufacturing high-current EV charging connectors, which feature thick copper terminal inserts, large mold sizes, strict dimensional tolerances, and demand long-term stable mass production with minimal defective rates. To match their multi-cavity charging plug mold and meet requirements of high clamping force, uniform plastic filling and safe manual insert loading, we customized a 160-ton vertical injection molding machine equipped with a single sliding table, delivering stable, high-volume continuous overmolding production for multi-cavity EV charging connector molds.

Case Details

160T High Clamping Force
160 tons locking force perfectly matches large-size multi-cavity EV charging connector molds. It provides uniform, powerful mold clamping pressure across the entire mold surface, completely eliminating flash, mold parting line misalignment and core displacement during high-volume production. Sufficient tonnage withstands high PVC/TPU injection pressure for thick-wall charging plug housings, protects expensive large molds from deformation, and maintains consistent product dimensional accuracy batch after batch.

320–680g Adjustable Injection Volume with Custom Screws
EV charging connectors adopt thick-wall insulation materials sensitive to temperature and shear. The wide-range injection capacity configuration ensures full plasticization and complete mold filling for large plug housings. Multiple optional screw specifications can be matched according to single-hole, double-hole and multi-gun charging plug designs. Optimized screw compression ratio avoids material overheating, carbonization and short-shot defects common in new energy plastic parts.

Heavy-Duty Single Sliding Table
The large single sliding table boasts ultra-large carrying capacity, capable of bearing heavy multi-cavity molds and pre-assembled charging terminal fixtures. While one station completes injection molding inside the machine, operators can finish terminal placement, wire fixing and finished product unloading on the external slide station simultaneously. Compared with turntable machines, it supports larger mold dimensions and heavier inserts, greatly lowering labor loading difficulty for big EV connectors, and lifting overall production efficiency by 25%–40% versus fixed-table vertical machines.

Full Servo Motor Hydraulic System
Full servo drive realizes ultra-precise multi-stage low-speed injection control, effectively solving common EV connector molding defects including material scorch, bubble generation and incomplete insulation wrapping. The servo system cuts power consumption by 35%–65% compared with traditional fixed pump machines, bringing remarkable energy savings for 24-hour uninterrupted production workshops with multiple equipment running simultaneously. It also delivers stable, repeatable injection pressure and speed to guarantee consistent insulation layer thickness of charging plugs.

Customer Production Benefits
① Remarkable Productivity Improvement: The heavy-load single sliding table supports synchronous loading and molding circulation, boosting overall production efficiency by 25%–40% compared with fixed-table vertical injection machines.
② Ultra-Stable Overmolding Performance: Full servo closed-loop control achieves smooth, controllable injection curves, drastically reducing EV connector defects like material burning, air bubbles and incomplete insulation filling.
③ Elevated Finished Product Yield Rate: Stable 160-ton high clamping force eliminates flash and mold deformation, realizing precise full encapsulation of thick copper charging terminals with uniform wall thickness and consistent finished product dimensions.
④ Optimized Unit Production Cost: Servo energy-saving system slashes power consumption, and high-yield multi-cavity molding reduces material waste and labor time, significantly lowering single-piece manufacturing cost for EV charging connectors.
⑤ Strong Compatibility for Product Iteration: Wide adjustable injection volume and large sliding table stroke adapt to various types of AC/DC charging plugs, supporting customers’ follow-up new product mold switching without replacing core equipment.

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