At Ergofuns, injection molding is the backbone of our plastic component production, especially for study chair parts like backrest frames, seat pans, armrests, chair bases, and footrests. This advanced process ensures every piece is strong, consistent, and ready for assembly.
1. Mold Preparation: Setting the Foundation for Accuracy
Our process starts with the design and preparation of precision-engineered molds for each chair component. These molds, crafted to exact specifications, capture market trends and ergonomic advances, ensuring every new product design meets the latest demands. New molds are regularly developed to introduce innovative products tailored for both aesthetics and function.
2. Material Feeding: Choosing the Right Resin
Quality begins with raw materials. We load top-grade plastic pellets—mainly virgin polypropylene (PP), valued for its strength and flexibility—into the injection molding machine's hopper. For chair parts that require superior structural strength, such as load-bearing frames or bases, we opt for robust nylon materials. This careful material selection ensures each part balances durability with comfort, perfectly suited for daily use in learning environments.
3. Melting and Injection: Bringing Components to Life
In this critical phase, plastic pellets are precisely heated until they reach a molten state. The liquid plastic is then injected into the mold cavity at high pressure, meticulously filling even the finest details. This ensures that every feature—down to the subtle curves and ergonomic contours—emerges with consistent accuracy for optimal fit and finish.
4. Cooling and Solidification: Maintaining Shape and Strength
Rapid and controlled cooling allows the plastic to solidify into its final form. During this stage, we fix the part securely within the mold to prevent any deformation resulting from temperature changes. This fundamental step is key to producing reliably strong and dimensionally stable components, vital for safety and longevity in children's chairs.
5. Ejection and Inspection: Delivering Quality with Every Part
Once cooled, the mold opens and the finished plastic part is ejected. Every component undergoes a thorough inspection—assessing aspects such as structural integrity, surface finish, and precise fitting. Only parts that meet our stringent standards proceed to the next phase, guaranteeing consistent quality for every batch.
6. Stacking and Storage: Ready for Assembly
Approved components are carefully stacked and stored in organized facilities, ensuring they remain protected and ready for seamless integration into the final assembly line or direct shipment. This systematic approach minimizes downtime and supports efficient order fulfillment for our global retail and distribution partners.
