1. In FPC production, molding occurs prior to quality inspection and packaging, marking the final step in the manufacturing process.

2. FPCs come in various shapes—square, round, long, tapered, regular, or irregular.

3. To achieve a uniform, aesthetically pleasing appearance that meets design specifications, FPC molding typically employs die-punch molding, cutting molding, or manual molding.

4. The choice of molding method depends on factors such as the quantity, precision, and delivery timeline required by the customer.

5. Let’s start with die punching. The core component of die punching is the mold, which varies for different FPC products.

6. Molds can be categorized by material, including steel molds and knife molds.

7. Steel molds, crafted from steel, offer high precision, withstand numerous stamping cycles, and resist deformation, making them the most commonly used option.

8. However, due to their heavy weight, they often require relocation during installation, and their cost can be high.

1. Steel molds are generally not produced in large quantities. They are suitable for FPC punching with a veneer size of 600mm or less; the die is lightweight and cost-effective, constructed from wood and steel blades. Accuracy is not high, making them suitable only for products and components that do not require stringent shape accuracy, such as reinforcing pieces, etc. (The term “mold” in this context refers exclusively to metal steel molds, while knife molds are not discussed further).

2. Based on accuracy, molds can be categorized as precision molds, ordinary molds, and simple molds. This classification involves three production methods: slow-moving, medium-moving, and fast-moving. Slow-moving molds are precision molds with a tolerance of ±0.05mm. These molds are made from high-quality steel that resists deformation but comes at a high price and lengthy production time. Unless customers specifically require a shape accuracy of ±0.05mm, this type of mold is generally not utilized. Medium-moving molds are ordinary molds with a tolerance of ±0.10mm, meeting most accuracy needs. They are moderately priced and stable in performance, making them the usual choice. Fast-moving molds are simple molds with an accuracy of ±0.2mm, slightly cheaper than ordinary molds, and are typically used for products with low outline tolerance.

3. A steel mold consists of an upper mold and a lower mold, where the lower mold serves as the base and the upper mold acts as the punching die. Once the mold is installed on the punching machine, the punching height must be adjusted using a test plate to determine the optimal punching force. This ensures that the FPC is cut according to the design drawing while avoiding damage to other areas that do not require punching. Typically, the mold is designed to process multiple pieces of FPC in one stamping operation, enhancing production efficiency. This approach allows the mold to be used repeatedly for mass production, thereby lowering unit production costs.

4. The second method is cutting and forming, generally employed for sample production and very small batches. Cutting and molding techniques include CNC knife cutting and laser molding. In CNC knife cutting, the cutting diagram is input into the computer, and the FPC is fixed on the equipment using positioning holes. The cutting head then moves along the lines of the drawing, shaping the FPC accordingly. This method can yield poor precision due to the relatively large blade and its susceptibility to damage, leading to long processing times and potential burrs or incomplete cuts. Previously, it was primarily used for cutting FPC samples, protective films, and electromagnetic films. However, the advent of laser cutting machines, which offer high accuracy (≤0.05mm) and cleaner edges with fewer burrs, has largely replaced CNC knife cutting. Most FPC samples are now produced this way. It’s worth noting that laser cutting, utilizing high-energy red/ultraviolet beams, may leave burn marks on the cutting surface, but these typically do not affect the appearance. It’s advisable to wipe the surface with a dust-free cloth and alcohol after production.

5. Lastly, there is manual molding, which involves using scissors, knives, and pens. This method is reserved for a few products that do not demand shape accuracy.

6. The above outlines several methods of FPC molding, highlighting their respective advantages, disadvantages, and suitable applications.
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