How a Precision Electronics Manufacturer Improved Dimensional Qualification by 14% with Mold Waterway Cleaning

This application overview explains precision mold cleaning for electronics manufacturing and the importance of stable cooling conditions.

Case at a Glance

Item	Project Information
Industry	Precision electronic components
Applications	Mobile phones, computers, and other high-end electronic devices
Mold characteristic	Very small cooling channel diameters
Previous cleaning method	High-pressure flushing
Main challenge	Micro-scale contamination, uneven cooling, and dimensional deviations
Solution	Customized Double-Easy mold waterway cleaning solution
Cleaning method	Precision nozzles with micro air-burst cleaning
Pressure control	SMC booster pump
Flow monitoring	Keyence ultrasonic flow meter
Dimensional qualification rate	Improved by 14%
Mold scrapping rate	Reduced by 42%
Reported annual savings	More than RMB 600,000

Customer Background

The customer is an electronics component manufacturer specializing in precision parts for mobile phones, computers, and other high-end electronic devices.

The molds used for these components require a high level of precision and contain very small cooling channels.

Because the cooling passages are small, even microscopic residue inside the mold waterways can affect cooling consistency.

Contamination inside the channels contributed to uneven cooling, dimensional deviations, and unstable component performance, making it difficult to meet the requirements of high-end electronics manufacturing.

The Challenge: Cleaning Very Small and Delicate Mold Waterways

Before introducing the Double-Easy solution, the manufacturer used high-pressure flushing to clean its mold cooling channels.

However, this method presented two major problems.

First, high-pressure flushing could not completely remove micro-scale contaminants from the fine internal cooling passages.

Second, excessive cleaning pressure could damage the delicate cooling channels.

In some cases, this resulted in mold failures and scrapping, creating additional mold replacement and production costs.

The manufacturer therefore needed a cleaning method that could remove microscopic contamination while controlling cleaning pressure to protect the internal mold structure.

A Customized Double-Easy Mold Waterway Cleaning Solution

To address the precision requirements of the electronics application, Double-Easy developed a customized mold waterway cleaning solution for the manufacturer.

The solution was built around the Double-Easy Mold Waterway Cleaning Machine.

For this application, the system used precision cleaning nozzles designed for very fine cooling channels.

The mold channel cleaning machine product range provides a starting point for discussing nozzle, flow-monitoring and pressure-control requirements.

The cleaning system generates a micro air-burst effect to remove microscopic residues from inside the mold waterways without damaging the internal surface of the mold.

The objective was to clean fine cooling passages while maintaining the precision required for electronic-component production.

Precision Cleaning Pressure and Flow Control

Controlling cleaning pressure was particularly important for this application because the mold cooling channels were small and delicate.

The Double-Easy system integrated:

1. An SMC booster pump

2. A Keyence ultrasonic flow meter

These components enabled the system to control cleaning pressure and flow rate during the cleaning process.

The controlled process helped prevent excessive pressure from damaging delicate mold structures while maintaining consistent cleaning performance.

Real-Time Flow Monitoring and Cleaning Evaluation

The equipment also supported real-time cleaning data comparison.

Operators could observe changes in flow rate before and after cleaning, providing a way to evaluate changes in the cooling passages during the cleaning process.

The Keyence ultrasonic flow meter was used to monitor these flow changes.

Designed for Continuous Production Requirements

The cleaning equipment was designed for stable continuous operation to support the production requirements of the electronics manufacturer.

Key components used in the system were sourced from internationally recognized brands.

These components were selected to support equipment durability and long-term reliability.

Measurable Results

After implementing the customized Double-Easy mold waterway cleaning solution, the manufacturer reported measurable improvements.

Performance In/dicator	Reported Result
Dimensional qualification rate	Improved by 14%
Mold scrapping rate	Reduced by 42%
Annual mold replacement and rework savings	More than RMB 600,000

Production stability and efficiency also improved after implementation.

Key Project Outcomes

The Double-Easy mold waterway cleaning solution helped the manufacturer:

1. Clean very small mold cooling channels

2. Remove micro-scale residues

3. Reduce the risk of damage caused by excessive cleaning pressure

4. Control cleaning pressure and flow rate

5. Monitor flow changes before and after cleaning

6. Improve dimensional qualification rates

7. Reduce mold scrapping

8. Reduce mold replacement and rework costs

9. Support stable continuous operation

What This Case Demonstrates

This case demonstrates the challenges involved in cleaning precision molds with very small cooling channels.

For this electronics component manufacturer, simply increasing flushing pressure was not sufficient. The previous high-pressure cleaning process could leave micro-scale contaminants inside the waterways and could also damage delicate cooling passages.

The Double-Easy solution combined precision cleaning nozzles, micro air-burst cleaning, controlled pressure, and ultrasonic flow monitoring.

The reported results show that dimensional qualification rates improved by 14%, mold scrapping rates decreased by 42%, and annual savings from mold replacement and rework costs exceeded RMB 600,000.

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