Vented Core Pins for Deep Boss Pillars in a Consumer Electronics Housing
Deep boss pillars in a 24-cavity consumer electronics housing mold trapped gas and wore through core pin tips every 400,000 shots, causing flow lines and costly mold pulls.
PROJECT OVERVIEW
"A consumer electronics OEM ran a 24-cavity mold producing high-gloss ABS/PC housings. Each cavity formed six deep boss pillars from straight core pins. Trapped gas in the blind boss holes produced flow lines on the outer shell, while tip wear degraded the boss surface after roughly 400,000 shots — triggering a full pin-set replacement every 3 to 4 months."
PAIN POINTS
- Deep blind boss holes trapped gas at the pin tip, causing flow lines on the high-gloss outer surface
- Core pin tips wore through after ~400,000 shots, degrading boss surface quality
- Full-set replacement every 3-4 months with mold pull, cutting into a 1.6M shots/year program
OUR SOLUTION
- Gas-release (flat-sided) core pins that vent the blind boss hole through the pin-to-bore clearance
- SKH51 (M2) pins hardened to HRC 62 with a 2-4 µm TiN coating for wear resistance
- Pins ground to ±0.002 mm with matched concentricity, CMM-verified under IATF 16949-level process control
Inlay core pin bushings — replaceable wear point without pulling the mold
Gas-release (flat-sided) core pins venting the blind boss hole
MEASURED RESULTS
| Core pin tip life | ~400,000 shots (uncoated SKD61) → 1,200,000+ shots (SKH51 + TiN), 3x improvement |
| Boss surface quality | Flow lines eliminated; surface consistent beyond 1,000,000 shots |
| Mold pulls for pin replacement | From every 3-4 months to once per year |
| Boss feature tolerance | Held at ±0.002 mm across the run |
YOUR APPLICATION MAY DIFFER
"For deep bosses, inserts and cored features in high-gloss parts, send us the part file — we will reply within 24 hours with the pin grade, venting and coating recommendation for your resin and shot count."