Molding parts that weight less than one third of an ounce with a circumference the size of a dime is one thing, but molding in five 0.125” diameter gold plated Beryllium copper springs adds another order of magnitude in complexity.
Sockets are molded in a 5" x 5" x 5" multi-cavity mold on a 25 ton Arburg vertical injection molding machine.
Springs are pre-loaded into a fixture during the injection cycle and dropped into the mold as it opens to insure an uninterrupted molding cycle: critical when molding Torlon.
Pins are precisely placed for each cycle. No post molding operations are required. Multiple cavities produce dozens of perfect parts per hour. Quality and cost both improve using this method of production.
Torlon 4203L, an unreinforced, lubricated Polyamide-imide (PAI) resin, was selected for the application as it has the best impact resistance and greatest elongation of all the Torlon grades.