Customer need
Suitable for main housings, handles, gearbox supports, motor brackets, battery pack housings, and charger structural parts of handheld drills, impact drills, angle grinders, and lithium-ion power tools. Power tools are compact, high-torque, and vibration-prone, often used outdoors and in low temperatures, with drops and bumps being everyday conditions.
Production problem
Common material challenges for power tool manufacturers: housings need sufficient rigidity to secure motors, bearings, and gears while withstanding drop impacts; screw bosses tend to crack during repeated assembly/disassembly; glass-fiber reinforced surfaces are prone to fiber float, affecting appearance and feel; standard reinforced nylon becomes brittle at low outdoor temperatures; some parts near motors or batteries may also require flame retardancy.
Modification solution
Recommended: [PA6 Black 30%] (glass-fiber reinforced) as the primary choice for load-bearing parts like main housings, gearbox supports, and motor brackets—offering a balance of rigidity, strength, and processability, with black suitable for tool aesthetics; for parts requiring higher impact resistance, such as handles, battery pack housings, and thin-wall clips, pair with [PA6 Black Resin Toughened]; for structural parts near motors with higher heat exposure, upgrade to [PA66 Black 30%] for better heat resistance; if flame retardancy is required, evaluate [PA6 Black Red Phosphorus Flame-Retardant Glass-Fiber]. Final combinations should be based on customer's actual drop and torque tests.
Result
Using the 'reinforced grade for rigidity, toughened grade for impact' combination approach achieves a better balance between structural strength and durability; replacing metal with plastic aids lightweighting for easier handling; concentrating material types on a few black grades simplifies procurement and production management.
How we worked
- Working condition analysis: Review stress, drop, heat, and appearance requirements for each part, classifying them into rigid and impact-resistant parts.
- Material combination: PA6 Black 30% as the base, with toughened grades, PA66 Black 30%, or flame-retardant glass-fiber grades as needed.
- Sample validation: Support mold trials and customer internal testing, focusing on screw bosses, clips, and surface fiber float.
- Stable supply: After confirming the solution, deliver in bulk, maintaining batch-to-batch consistency of black material.
| Item | Before | After |
|---|---|---|
| Reinforcement approach | Glass-fiber reinforced + toughened combination | |
| Recommended materials | PA6 Black 30% / PA6 Black Resin Toughened / PA66 Black 30% | |
| Key focus | Rigidity, drop resistance, surface appearance | |
| Flame retardancy option | Flame-retardant glass-fiber grades can be evaluated if needed |
Service
Provide material combination recommendations based on part function; supply sample materials and support customer mold trials, offering process and formulation guidance for issues like fiber float, warpage, and screw boss cracking; after validation, supply in bulk per order, ensuring consistent black color across batches.