The NVC (Nickel-Vacuum Coating) process has emerged as a highly effective alternative to traditional machining methods for mold production. Compared to conventional machining techniques, the NVC process offers several advantages that lead to cost savings, reduced production times, improved mold longevity, and higher-quality molded products. Here are the key benefits of the NVC process:

1. Cost Reduction, Shorter Production Cycles, and Long Mold Lifespan

One of the major advantages of the NVC process is its ability to significantly reduce production costs and cycle times, while extending the mold’s service life. For example, in the production of Ford automotive dashboard and lighting lenses, the gas-phase deposition nickel shell-backer molds made through the NVC process have been shown to reduce costs by 30% and shorten the production cycle by 60% when compared to traditional machining methods with steel injection molds. Moreover, after molding 19,000 pieces, these molds show no sign of damage, demonstrating their impressive durability and long lifespan.

2. Reduced Workpiece Warping and Deformation

The NVC process also significantly minimizes warping and deformation of molded parts. Through CAE (Computer-Aided Engineering) simulations, it has been shown that molds used for manufacturing lighting lenses with the gas-phase deposition nickel shell-backer technology experience only a 0.9°C temperature variation during the molding process. In contrast, traditional steel molds often show 4°C to 7°C of temperature fluctuation. This lower temperature variation in the NVC process mold leads to a significant reduction in residual stresses, which are the primary cause of part warping and deformation in injection molding. By maintaining a more uniform temperature, the NVC molds ensure a higher-quality finish with minimal distortion.

3. Shortened Injection Molding Cycles and Improved Product Quality

The NVC process is also beneficial in terms of improving cycle times and enhancing the overall quality of the molded product. For the same lighting lens molding application, traditional steel molds typically require 48 seconds for each injection cycle. However, using the gas-phase deposition nickel shell-backer mold from the NVC process, the cycle time can be reduced to as low as 30 seconds when the mold temperature is lowered to 49°C. This reduction in cycle time leads to a significant decrease in the cost per molded part, ultimately improving production efficiency and reducing manufacturing expenses.

4. Enhanced Thermal Conductivity for Faster Cooling

In addition to the direct benefits mentioned above, the NVC process provides superior thermal conductivity due to the nickel shell applied during the coating process. This enables faster and more uniform cooling of the molded parts, which helps reduce the overall injection cycle time and further improves part quality by minimizing thermal gradients within the mold. Faster cooling not only accelerates the production process but also helps in maintaining consistent dimensional accuracy of the molded parts.

5. High Durability and Resistance to Wear

Another key benefit of the NVC process is its ability to produce molds with enhanced durability. The nickel shell provides excellent resistance to wear and corrosion, ensuring the mold’s longevity. Traditional molds, especially those made from steel, are prone to wear and corrosion over time, which can lead to defects in the molded parts and the need for frequent mold repairs. In contrast, molds produced using the NVC process can withstand the rigors of high-volume production with minimal wear and tear.

Conclusion: NVC Process – A Game Changer in Molding

In conclusion, the NVC (Nickel-Vacuum Coating) process offers significant improvements over traditional machining techniques in terms of cost-effectiveness, production efficiency, and mold durability. With its ability to reduce production costs, shorten cycle times, and improve the quality of molded parts, the NVC process is rapidly becoming a preferred choice in industries such as automotive manufacturing, electronic components, and consumer products. By leveraging the advanced capabilities of gas-phase deposition nickel shell-backer molds, manufacturers can achieve better quality, faster production, and lower costs—all while ensuring long-lasting mold performance.