Plastic Injection Molding of an ABS Ready to Assemble Computer Monitor Housing

Our motto here at ASPEC is “We make it happen!” which is just what we did with the ready to assemble computer monitor housing highlighted here. This product was far more than just an injection molding project. It involved a collaborative development strategy to transform the housing from a die cast metal product to a lightweight ABS alternative that was sturdy, strong, and provided the rated EMI/RFI shielding.

Before producing a conceptual SLA model, we fine-tuned the design to alleviate potential sink marks left by the ribs and bosses of the injection mold. We forwarded the mold CAD files and Solid Models to the tooling vendor for phase one construction, and when completed, executed a sample run for dimensional inspection and part approval. Continuing operations involved texturing the mold cavity surface, construction of electro formed spray mask for use in the RFI shielding process, and creating an epoxy-cast ultrasonic welding nest for adding the brass threaded inserts.

Featuring overall dimensions of 12-⅛” in length x 9-½” in width x 1-½” in height, we produced these components on our 225 ton press from a 19 oz. shot size of flame retardant ABS plastic. Critical quality inspections validated that the ±0.010 tolerances between mounting holes allowed a tight match up when assembled and the nickel over copper plating provided the rated barrier protection. The components were bagged, stack-packed, and shipped to the customer ready for assembly.

Current production of these monitor housings is 200 units/month. If you are interested in learning more about this project, or have a metal-to-plastic conversion project you are considering, we would welcome the opportunity to hear the details. Contact us today.