hlhrapidlimited

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Custom Automotive Components Made with Injection Molding: A Big Change in Manufacturing

The automotive industry focuses on innovation, accuracy, and efficiency. Injection molding plays a big role in driving this progress, especially for custom car parts. From detailed interior pieces to tough under-the-hood components, injection molding stands out for making high-quality, affordable parts designed to fit specific needs.

What is Injection Molding?

Injection molding is a manufacturing process where molten plastic or other materials are injected into a mold cavity, allowed to cool, and then ejected as a finished part. This method is especially popular in the automotive sector for producing components with high precision and repeatability.

Why Choose Injection Molding for Automotive Parts?

Here are the key reasons why injection molding is ideal for creating custom automotive components:

1. Design Flexibility 

   Injection molding allows for the creation of highly complex and detailed designs that would be difficult or expensive with other manufacturing methods. This makes it perfect for producing custom parts like dashboards, air vents, and light covers.

2. Material Versatility

   The process supports a wide range of materials, including: 

Thermoplastics like ABS, polycarbonate, and polypropylene for lightweight, durable parts. 

Elastomer for flexible components like seals and gaskets. 

Composite materials for enhanced strength and thermal resistance. 

3. Cost Efficiency for Large Volumes

While the initial tooling costs for injection molding can be expensive, the cost per part drops a lot as production numbers go up. This makes it a cheaper option for mass production.

4. Durability and Quality

Injection molding creates parts with reliable quality, precise measurements, and smooth surfaces, which are crucial for meeting the high standards of the automotive industry.

5.Speed and Scalability 

Once the mold is made, the process is very quick, allowing manufacturers to meet deadlines and increase production to match demand.

Applications in Automotive Manufacturing

Injection molding is used extensively for a variety of automotive components, including: 

Interior Components: Dashboards, door panels, cup holders, and glove boxes. 

Exterior Parts: Bumpers, grilles, and side mirrors. 

Engine Bay Parts: Air intake manifolds, battery housings, and fluid reservoirs. 

Lighting: Headlight and taillight casings. 

Customization Opportunities with Injection Molding

Customization is important in the automotive industry to meet different customer needs and stand out from competitors. Injection molding helps with this by:

Custom Designs: Unique shapes, textures, and finishes. 

Branding: Logos and patterns built into the parts. 

Special Materials: Heat resistance, UV protection, and strength suited for specific conditions. 

Sustainability in Injection Molding

Modern injection molding techniques focus on reducing waste and improving energy efficiency. Many manufacturers are incorporating: 

Recycled materials to minimize environmental impact. 

Bioplastics for eco-friendly components. 

Energy-efficient machinery to lower carbon footprints.

Choosing the Right Partner for Injection Molding

For businesses in the automotive sector, selecting an experienced injection molding partner is crucial. Look for a provider with: 

Expertise in custom designs and tooling. 

A track record of high-quality production. 

Knowledge of automotive industry standards and certifications. 

Injection molding is an essential part of today’s car manufacturing, providing high precision, efficiency, and customization. Whether you need light parts for better fuel economy or strong parts for tough conditions, this process produces results that meet and often exceed industry standards.

Manufacturers can stay competitive by using injection molding for custom car parts, making products that are innovative, functional, and eco-friendly.

Want to see how injection molding can improve your automotive parts? Contact us to get advice from the experts

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High-Quality CNC Rapid Prototyping for Plastic and Metals

Rapid prototyping has become a foundation for developing products faster, accurately, and cost-effectively. As innovation speeds up across sectors like automotive, aerospace, electronics, and medical devices, the need for reliable prototypes that closely mimic final products have grown exponentially. This demand has been met largely through machining, which excels in creating high-quality prototypes from both plastic and metal materials.

HLH Rapid, a well-known provider in the rapid prototyping space, uses advanced CNC machining to deliver fast, high-precision prototypes that help clients bring their product concepts to life.

This article explores how CNC rapid prototyping works, the materials commonly used, and the advantages that HLH Rapid offers as a manufacturer.

More about CNC Rapid Prototyping:

Unlike traditional manufacturing methods, CNC machining does not require custom tooling, making it faster and more economical for producing small batches or one-off prototypes. CNC machines are controlled by CAD (Computer-Aided Design) files, which provide detailed instructions on how to shape and carve each part.

This process is particularly popular for rapid prototyping because it allows engineers to test the form, fit, and function of a design before mass production. By creating prototypes in a variety of materials, CNC machining allows designers to validate their ideas and adjust designs early, reducing the risk of costly errors down the line.

Materials in CNC Rapid Prototyping: Plastic and Metal

The choice of material in CNC rapid prototyping plays a critical role in the final prototype's performance and quality. CNC machining supports a wide variety of materials, but plastics and metals are among the most used for their versatility, strength, and functionality.

1. Plastic Prototyping

Plastics are widely used in prototyping for applications that require lightweight, non-conductive, or corrosion-resistant properties. CNC-machined plastic prototypes can mimic the characteristics of various thermoplastics and thermosetting materials, making them ideal for industries like consumer electronics and medical devices.

ABS (Acrylonitrile Butadiene Styrene): Known for its toughness and ease of machining, ABS is a popular plastic for functional prototypes.

Nylon: This durable, versatile plastic is often used for parts that need strength and resilience.

POM (Polyoxymethylene): Also known as Delrin, POM is excellent for producing precision parts with high stiffness and dimensional stability.

PMMA (Acrylic): For clear prototypes or aesthetic models, acrylic is commonly used as it provides transparency and a glass-like finish.

2. Metal Prototyping

When strength, thermal stability, and electrical conductivity are priorities, metals become the preferred choice for CNC rapid prototyping. These prototypes are particularly valuable in industries such as aerospace, automotive, and robotics, where functional testing of metal components is essential.

Aluminum: With excellent machinability, lightweight properties, and corrosion resistance, aluminum is a go-to metal for creating prototypes that need strength without added weight.

Stainless Steel: Ideal for high-strength applications, stainless steel offers excellent corrosion resistance and durability.

Brass: Known for its machinability and attractive finish, brass is often used in prototypes requiring electrical conductivity or a polished appearance.

Titanium: Although challenging to machine, titanium offers exceptional strength-to-weight ratios and is used for prototypes in high-performance applications.

Advantages of CNC Rapid Prototyping

CNC rapid prototyping has multiple advantages over traditional methods, making it a preferred choice in modern manufacturing:

1. Precision and Accuracy

CNC machines operate with exceptional accuracy, often achieving tolerances within a few micrometers. This precision is crucial in prototyping, where even minor inaccuracies can lead to functional issues in the final product.

2. Speed and Efficiency

Since CNC machining does not require custom tooling, it can start production almost immediately after design files are prepared. This rapid turnaround is invaluable for companies that need to iterate designs quickly or meet tight project deadlines.

3. Material Versatility

With CNC rapid prototyping, designers can choose from a vast selection of materials. This flexibility allows them to test their prototypes in materials that closely simulate the final product, enabling a more accurate evaluation of their design.

4. Scalability

Though primarily used for small-batch production, CNC rapid prototyping can scale easily. This scalability makes CNC suitable for both low-volume and high-volume production runs, depending on the needs of the project.

5. Cost-Effectiveness

Without the need for molds or tooling, CNC rapid prototyping significantly reduces upfront costs. This cost advantage is especially beneficial for companies developing custom, short-run parts or testing multiple iterations of a design.

How HLH Rapid Excels in CNC Rapid Prototyping?

HLH Rapid specializes in high-quality CNC rapid prototyping for plastic and metal components. The main approach combines the latest technology with expertise across various industries, delivering precision prototypes that meet client specifications.

Cutting-Edge CNC Manufacturing Service

Expert Engineering Team

Quality Assurance

Flexible Lead Times

Applications for CNC Rapid Prototyping with HLH Rapid

The versatility and precision of CNC rapid prototyping make it applicable to various sectors, allowing companies to test concepts in real-world conditions:

Aerospace: High-performance prototypes in lightweight metals such as titanium and aluminum for aerospace components that require strength without added mass.

Automotive: Functional prototypes that undergo durability and performance testing, using materials like stainless steel or ABS plastic.

Medical Devices: Precise, sterile prototypes for surgical tools or diagnostic devices, enabling realistic testing before regulatory approval.

Consumer Electronics: Plastic prototypes that mimic final production parts, allowing designers to assess aesthetics and functionality.

In a nutshell, high-quality CNC rapid prototyping has become an important tool for today’s manufacturers, helping bring ideas from concept to reality way faster and efficiently. By providing high quality prototypes in plastic or metal, CNC machining supports industries that demand both speed and accuracy.

Would you like to talk to an expert? Discuss your project with us and upload your file here

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All you need to know about Custom Rapid Prototypes – HLH Rapid

In manufacturing, product development needs to be fast, precise, and flexible. Custom rapid prototyping helps industries quickly turn CAD designs into real products. From unique ideas to testing, these prototypes are changing how businesses innovate.

Brief Summary of Custom Rapid Prototyping  

Custom rapid prototyping involves creating tailored models or components directly from a digital design file. Using techniques such as 3D printing, CNC machining, and injection molding, these prototypes are crafted to meet specific project needs, ensuring they are precise and fit for their intended purpose. 

Unlike standard prototyping, custom rapid prototypes are designed with the end user’s unique requirements in mind. This personalization enables better testing, improved functionality, and faster iterations. 

Key Advantages of Custom Rapid Prototyping 

Speed to Market 

Rapid prototyping drastically reduces lead times, enabling businesses to bring their products to market faster. Customization ensures that every iteration is closer to the final product, saving time on revisions. 

Cost Efficiency

By identifying design flaws early, custom prototypes eliminate the need for costly adjustments in later production stages. Additionally, producing only what’s needed minimizes waste. 

Design Flexibility 

With custom prototypes, designers can test multiple variations without committing to full-scale production. This flexibility fosters innovation and creativity. 

Functional Testing 

Custom prototypes are not just visual models, they can be functional parts. This allows businesses to assess performance, durability, and usability in real-world conditions. 

Enhanced Communication 

Physical prototypes make it easier for teams, stakeholders, and clients to visualize the product, bridging the gap between concept and reality. 

Popular Methods for Creating Custom Prototypes 

1. 3D Printing (Additive Manufacturing)  

   Ideal for complex geometries and quick turnarounds, 3D printing is perfect for producing intricate designs using materials like resin, nylon, and metals. 

2. CNC Machining  

   For high-precision prototypes with superior surface finishes, CNC machining excels. It’s commonly used for metal and plastic parts requiring tight tolerances. 

3. Vacuum Casting  

   This process replicates prototypes using silicone molds, offering excellent detail and material options for small production runs. 

4. Sheet Metal Fabrication 

   A great choice for creating durable and functional prototypes in industries like aerospace and automotive. 

Applications of Custom Rapid Prototyping 

Aerospace: Lightweight, high-strength parts for testing and assembly. 

Automotive: Prototypes for components like engine parts, dashboards, and lighting systems. 

Medical Devices: Custom models for surgical tools, implants, and diagnostics equipment. 

Consumer Products: Iterations of gadgets, packaging, and home appliances. 

Why Choose Custom Prototypes?

Custom rapid prototypes are designed specifically for your project, ensuring they meet your goals. Whether you need unique dimensions, specialized materials, or a specific functionality, custom prototypes allow for unmatched precision and personalization. 

Conclusion 

Custom rapid prototyping is transforming industries by making innovation faster, more efficient, and highly accurate. With advanced manufacturing methods, businesses can quickly bring their ideas to life. Whether you're creating a new product or improving an old one, custom prototypes make the process smoother and more successful.

Need custom rapid prototypes for your next product development?  Contact us to learn how we can help you with your next project. Submit your CAD file here

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High-Quality CNC Rapid Prototyping for Plastic and Metals

Rapid prototyping has become a foundation for developing products faster, accurately, and cost-effectively. As innovation speeds up across sectors like automotive, aerospace, electronics, and medical devices, the need for reliable prototypes that closely mimic final products have grown exponentially. This demand has been met largely through machining, which excels in creating high-quality prototypes from both plastic and metal materials.

HLH Rapid, a well-known provider in the rapid prototyping space, uses advanced CNC machining to deliver fast, high-precision prototypes that help clients bring their product concepts to life.

This article explores how CNC rapid prototyping works, the materials commonly used, and the advantages that HLH Rapid offers as a manufacturer.

More about CNC Rapid Prototyping:

Unlike traditional manufacturing methods, CNC machining does not require custom tooling, making it faster and more economical for producing small batches or one-off prototypes. CNC machines are controlled by CAD (Computer-Aided Design) files, which provide detailed instructions on how to shape and carve each part.

This process is particularly popular for rapid prototyping because it allows engineers to test the form, fit, and function of a design before mass production. By creating prototypes in a variety of materials, CNC machining allows designers to validate their ideas and adjust designs early, reducing the risk of costly errors down the line.

Materials in CNC Rapid Prototyping: Plastic and Metal

The choice of material in CNC rapid prototyping plays a critical role in the final prototype's performance and quality. CNC machining supports a wide variety of materials, but plastics and metals are among the most used for their versatility, strength, and functionality.

1. Plastic Prototyping

Plastics are widely used in prototyping for applications that require lightweight, non-conductive, or corrosion-resistant properties. CNC-machined plastic prototypes can mimic the characteristics of various thermoplastics and thermosetting materials, making them ideal for industries like consumer electronics and medical devices.

ABS (Acrylonitrile Butadiene Styrene): Known for its toughness and ease of machining, ABS is a popular plastic for functional prototypes.

Nylon: This durable, versatile plastic is often used for parts that need strength and resilience.

POM (Polyoxymethylene): Also known as Delrin, POM is excellent for producing precision parts with high stiffness and dimensional stability.

PMMA (Acrylic): For clear prototypes or aesthetic models, acrylic is commonly used as it provides transparency and a glass-like finish.

2. Metal Prototyping

When strength, thermal stability, and electrical conductivity are priorities, metals become the preferred choice for CNC rapid prototyping. These prototypes are particularly valuable in industries such as aerospace, automotive, and robotics, where functional testing of metal components is essential.

Aluminum: With excellent machinability, lightweight properties, and corrosion resistance, aluminum is a go-to metal for creating prototypes that need strength without added weight.

Stainless Steel: Ideal for high-strength applications, stainless steel offers excellent corrosion resistance and durability.

Brass: Known for its machinability and attractive finish, brass is often used in prototypes requiring electrical conductivity or a polished appearance.

Titanium: Although challenging to machine, titanium offers exceptional strength-to-weight ratios and is used for prototypes in high-performance applications.

Advantages of CNC Rapid Prototyping

CNC rapid prototyping has multiple advantages over traditional methods, making it a preferred choice in modern manufacturing:

1. Precision and Accuracy

CNC machines operate with exceptional accuracy, often achieving tolerances within a few micrometers. This precision is crucial in prototyping, where even minor inaccuracies can lead to functional issues in the final product.

2. Speed and Efficiency

Since CNC machining does not require custom tooling, it can start production almost immediately after design files are prepared. This rapid turnaround is invaluable for companies that need to iterate designs quickly or meet tight project deadlines.

3. Material Versatility

With CNC rapid prototyping, designers can choose from a vast selection of materials. This flexibility allows them to test their prototypes in materials that closely simulate the final product, enabling a more accurate evaluation of their design.

4. Scalability

Though primarily used for small-batch production, CNC rapid prototyping can scale easily. This scalability makes CNC suitable for both low-volume and high-volume production runs, depending on the needs of the project.

5. Cost-Effectiveness

Without the need for molds or tooling, CNC rapid prototyping significantly reduces upfront costs. This cost advantage is especially beneficial for companies developing custom, short-run parts or testing multiple iterations of a design.

How HLH Rapid Excels in CNC Rapid Prototyping?

HLH Rapid specializes in high-quality CNC rapid prototyping for plastic and metal components. The main approach combines the latest technology with expertise across various industries, delivering precision prototypes that meet client specifications.

Cutting-Edge CNC Manufacturing Service

Expert Engineering Team

Quality Assurance

Flexible Lead Times

Applications for CNC Rapid Prototyping with HLH Rapid

The versatility and precision of CNC rapid prototyping make it applicable to various sectors, allowing companies to test concepts in real-world conditions:

Aerospace: High-performance prototypes in lightweight metals such as titanium and aluminum for aerospace components that require strength without added mass.

Automotive: Functional prototypes that undergo durability and performance testing, using materials like stainless steel or ABS plastic.

Medical Devices: Precise, sterile prototypes for surgical tools or diagnostic devices, enabling realistic testing before regulatory approval.

Consumer Electronics: Plastic prototypes that mimic final production parts, allowing designers to assess aesthetics and functionality.

High-Quality CNC Rapid Prototyping for Plastic and Metals

Rapid prototyping has become a foundation for developing products faster, accurately, and cost-effectively. As innovation speeds up across sectors like automotive, aerospace, electronics, and medical devices, the need for reliable prototypes that closely mimic final products have grown exponentially. This demand has been met largely through machining, which excels in creating high-quality prototypes from both plastic and metal materials.

HLH Rapid, a well-known provider in the rapid prototyping space, uses advanced CNC machining to deliver fast, high-precision prototypes that help clients bring their product concepts to life.

This article explores how CNC rapid prototyping works, the materials commonly used, and the advantages that HLH Rapid offers as a manufacturer.

More about CNC Rapid Prototyping:

Unlike traditional manufacturing methods, CNC machining does not require custom tooling, making it faster and more economical for producing small batches or one-off prototypes. CNC machines are controlled by CAD (Computer-Aided Design) files, which provide detailed instructions on how to shape and carve each part.

This process is particularly popular for rapid prototyping because it allows engineers to test the form, fit, and function of a design before mass production. By creating prototypes in a variety of materials, CNC machining allows designers to validate their ideas and adjust designs early, reducing the risk of costly errors down the line.

Materials in CNC Rapid Prototyping: Plastic and Metal

The choice of material in CNC rapid prototyping plays a critical role in the final prototype's performance and quality. CNC machining supports a wide variety of materials, but plastics and metals are among the most used for their versatility, strength, and functionality.

1. Plastic Prototyping

Plastics are widely used in prototyping for applications that require lightweight, non-conductive, or corrosion-resistant properties. CNC-machined plastic prototypes can mimic the characteristics of various thermoplastics and thermosetting materials, making them ideal for industries like consumer electronics and medical devices.

ABS (Acrylonitrile Butadiene Styrene): Known for its toughness and ease of machining, ABS is a popular plastic for functional prototypes.

Nylon: This durable, versatile plastic is often used for parts that need strength and resilience.

POM (Polyoxymethylene): Also known as Delrin, POM is excellent for producing precision parts with high stiffness and dimensional stability.

PMMA (Acrylic): For clear prototypes or aesthetic models, acrylic is commonly used as it provides transparency and a glass-like finish.

2. Metal Prototyping

When strength, thermal stability, and electrical conductivity are priorities, metals become the preferred choice for CNC rapid prototyping. These prototypes are particularly valuable in industries such as aerospace, automotive, and robotics, where functional testing of metal components is essential.

Aluminum: With excellent machinability, lightweight properties, and corrosion resistance, aluminum is a go-to metal for creating prototypes that need strength without added weight.

Stainless Steel: Ideal for high-strength applications, stainless steel offers excellent corrosion resistance and durability.

Brass: Known for its machinability and attractive finish, brass is often used in prototypes requiring electrical conductivity or a polished appearance.

Titanium: Although challenging to machine, titanium offers exceptional strength-to-weight ratios and is used for prototypes in high-performance applications.

Advantages of CNC Rapid Prototyping

CNC rapid prototyping has multiple advantages over traditional methods, making it a preferred choice in modern manufacturing:

1. Precision and Accuracy

CNC machines operate with exceptional accuracy, often achieving tolerances within a few micrometers. This precision is crucial in prototyping, where even minor inaccuracies can lead to functional issues in the final product.

2. Speed and Efficiency

Since CNC machining does not require custom tooling, it can start production almost immediately after design files are prepared. This rapid turnaround is invaluable for companies that need to iterate designs quickly or meet tight project deadlines.

3. Material Versatility

With CNC rapid prototyping, designers can choose from a vast selection of materials. This flexibility allows them to test their prototypes in materials that closely simulate the final product, enabling a more accurate evaluation of their design.

4. Scalability

Though primarily used for small-batch production, CNC rapid prototyping can scale easily. This scalability makes CNC suitable for both low-volume and high-volume production runs, depending on the needs of the project.

5. Cost-Effectiveness

Without the need for molds or tooling, CNC rapid prototyping significantly reduces upfront costs. This cost advantage is especially beneficial for companies developing custom, short-run parts or testing multiple iterations of a design.

How HLH Rapid Excels in CNC Rapid Prototyping?

HLH Rapid specializes in high-quality CNC rapid prototyping for plastic and metal components. The main approach combines the latest technology with expertise across various industries, delivering precision prototypes that meet client specifications.

Cutting-Edge CNC Manufacturing Service

Expert Engineering Team

Quality Assurance

Flexible Lead Times

Applications for CNC Rapid Prototyping with HLH Rapid

The versatility and precision of CNC rapid prototyping make it applicable to various sectors, allowing companies to test concepts in real-world conditions:

Aerospace: High-performance prototypes in lightweight metals such as titanium and aluminum for aerospace components that require strength without added mass.

Automotive: Functional prototypes that undergo durability and performance testing, using materials like stainless steel or ABS plastic.

Medical Devices: Precise, sterile prototypes for surgical tools or diagnostic devices, enabling realistic testing before regulatory approval.

Consumer Electronics: Plastic prototypes that mimic final production parts, allowing designers to assess aesthetics and functionality.

In a nutshell, high-quality CNC rapid prototyping has become an important tool for today’s manufacturers, helping bring ideas from concept to reality way faster and efficiently. By providing high quality prototypes in plastic or metal, CNC machining supports industries that demand both speed and accuracy.

Would you like to talk to an expert? Discuss your project with us and upload your file here

[hlhrapidlimited]

Materials for Low Volume Injection Molding: What to Consider?

When it comes to low volume injection molding, choosing the right material is important to ensure the proper product development output.

Material selection affects everything from the cost and performance of the part to the production speed and durability of the mold. Whether you’re developing a prototype or producing small batches of custom parts, understanding what to consider when selecting materials will help you achieve the best results.

In this blog, we'll learn the key factors you should keep in mind when choosing materials for low volume injection molding.

The first thing to consider is the specific requirements of your project. Here are the following questions that can be checked prior to implementation:

What are the mechanical properties needed?

If you need to a strong, flexible, or heat-resistant, this will determine the type of material you choose.

What environment will the part be exposed to?

Does the part need to withstand high temperatures, moisture, or chemicals? Choosing a material that performs well under these conditions is advantage

How complex is the design?

Some materials flow better into complex molds, making them ideal for intricate designs or parts with fine details.

2. Common Material Choices for Low Volume Injection Molding

Here are some of the most used materials in low volume injection molding:

a) ABS (Acrylonitrile Butadiene Styrene)

ABS is a popular choice for injection molding due to its good balance of strength, flexibility, and ease of molding. It’s often used for prototypes or parts that require moderate durability. ABS is also cost-effective, making it a go-to material for low-volume production.

Best for: Consumer products, automotive components, and electronic housing.

b) Polypropylene (PP)

Polypropylene is lightweight, flexible, and resistant to chemicals, making it ideal for parts exposed to moisture or chemicals. It’s commonly used in packaging, medical devices, and household products.

Best for: Packaging, medical devices, and storage containers.

c)Polycarbonate (PC)

For projects requiring high impact resistance and clarity, polycarbonate is a great option. It’s commonly used for safety equipment, transparent parts, and components requiring toughness.

Best for: Optical lenses, safety helmets, and protective covers.

d)Nylon (Polyamide)

Nylon offers excellent strength, abrasion resistance, and heat tolerance. It’s often used for mechanical parts or components that will be exposed to friction and wear.

Best for: Gears, bearings, and other industrial components.

e) Thermoplastic Elastomers (TPE)

TPE combines the properties of rubber with the ease of plastic molding. It’s great for parts that need to be flexible or soft, like grips or seals.

Best for: Soft-touch grips, over-molded parts, and seals.

3.Mold Considerations

In low volume injection molding, the type of mold used can also impact your material selection. For example, if you're using aluminum molds—which are often preferred in low volume production due to their lower cost—it's important to choose materials that are compatible with these molds. Aluminum molds are not as durable as steel molds, so choosing materials that mold easily and don’t cause excessive wear is important.

4.Material Costs

Budget plays a crucial role in material selection. In low volume production, it’s important to find a balance between the performance of the material and the overall cost. Some high-performance materials like PEEK or ULTEM offer great strength and heat resistance but can be expensive. For low volume runs, you may need to assess whether you truly need those high-end properties or if a more affordable option like ABS or polypropylene will suffice.

5.Lead Times and Availability

When working on a low volume project, the timeline is often critical. Some materials are more readily available than others. Make sure to check the lead times for your chosen material to ensure it aligns with your production schedule. In some cases, opting for more commonly available material can help speed up the overall process.

6.Recyclability and Sustainability

Sustainability is becoming a bigger concern in manufacturing. If you're focused on reducing environmental impact, consider materials that are recyclable or come from renewable sources. For example, recycled plastics or biodegradable polymers can be excellent choices, especially for companies aiming for eco-friendly practices.

7.Testing and Prototyping

Before finalizing your material choice, it's important to test how well the material meets your specific requirements. Low volume injection molding is ideal for prototyping, allowing you to try out different materials and see how they perform under real-world conditions.

Choosing the right material for low volume injection molding is key to achieving the right balance between cost, durability, and performance. By considering your project’s specific requirements—such as strength, flexibility, chemical resistance, and design complexity—you can make informed decisions about the best material to use. Keep mold compatibility, material costs, and sustainability in mind to ensure your low volume production is both efficient and cost-effective.

With the right material, low volume injection molding can deliver high-quality, functional prototypes or limited-run products that meet your exact needs. For more details, visit https://hlhrapid.com/rapid-injection-moulding/

Would you like to discuss your project with the experts? Submit your CAD file here

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Subtractive Manufacturing: What You Need to Know?

Learn more about what is subtractive Manufacturing:

Subtractive manufacturing is a process where material is removed from a solid block, bar, or sheet of material to create a desired part or product. This contrasts with additive manufacturing, where material is built up layer by layer to form an object. In subtractive manufacturing, tools like drills, lathes, and mills cut away material to achieve the final shape.

Common materials used in subtractive manufacturing include metals (such as aluminum, steel, and titanium), plastics, and composites.

How Does Subtractive Manufacturing Work?

Subtractive manufacturing typically involves CNC machines, which are highly automated tools capable of cutting, drilling, milling, or grinding away excess material from a workpiece. Here's a simplified version of the typical workflow:

1.Design Phase (CAD): The process starts with a 3D CAD model. This digital file represents the final part and is the blueprint for the manufacturing process.

2.CAM Software: The CAD model is imported into - CAM software, which generates instructions for the CNC machine, detailing tool paths, cutting sequences, and more.

3.Machining: The CNC machine executes these instructions, removing material from the workpiece using cutting tools like end mills, drills, or lathes. The machine works layer by layer or face by face, gradually refining the part.

4.Post-Processing: After machining, the part may undergo additional steps like polishing, deburring, or surface treatments to achieve the desired finish and tolerances.

Common Subtractive Manufacturing Techniques

Several techniques fall under the umbrella of subtractive manufacturing. Some of the most widely used include:

1.CNC Milling

In CNC milling, spinning cutting tools remove material from the workpiece, often from different angles. This process is ideal for making complex shapes, detailed surfaces, and precise parts.

2.CNC Turning

Turning involves spinning the workpiece while a fixed cutting tool removes material. This process is commonly used to make round items like shafts, bolts, and bushings.

3.CNC Drilling

Drilling uses a rotating tool to make holes in the workpiece. CNC drilling is accurate and can create holes of different sizes and depths, with the same results every time.

4.CNC Grinding

Grinding uses an abrasive wheel to remove small amounts of material and is often used to get smooth surfaces or very precise sizes.

Applications of Subtractive Manufacturing

Subtractive manufacturing is utilized across many industries where precision, durability, and high-quality finishes are critical. Here are a few examples:

Aerospace: Components like turbine blades, brackets, and engine parts are often made using CNC machining due to the need for tight tolerances and high-performance materials.

Automotive: Subtractive methods are used to produce engine blocks, transmission parts, and other vital components.

Medical Devices: CNC machining is essential for producing surgical tools, prosthetics, and implantable devices with precision.

Consumer Electronics: Custom enclosures, heat sinks, and other intricate parts can be crafted through subtractive manufacturing.

Advantages of Subtractive Manufacturing

1.High Precision

Subtractive manufacturing methods, particularly CNC machining, offer unparalleled accuracy and tolerances. This makes it the go-to choice for industries that require exact specifications, such as aerospace and medical device manufacturing.

2.Excellent Surface Finish

Because subtractive processes gradually remove material with fine-tuned tools, the resulting surface finishes are often superior to those achieved with additive manufacturing. This reduces the need for extensive post-processing.

3.Material Variety

Subtractive manufacturing can work with a wide range of materials, from metals and plastics to advanced composites. The flexibility to choose from different materials allows for parts with specific properties like strength, heat resistance, or lightweight construction.

4.Scalability

Subtractive manufacturing is ideal for both prototyping and high-volume production. Once the design is set, CNC machines can produce large quantities of parts quickly and consistently.

5.Established Technology

The maturity of subtractive manufacturing technology means it's a trusted, reliable option for many manufacturers. The tooling, machines, and software used have been refined over decades, leading to increased efficiency and lower costs over time.

Here are some Limitations of Subtractive Manufacturing

While subtractive manufacturing has many strengths, it also comes with a few limitations:

Material Waste: Since material is removed during the process, it naturally creates more waste compared to additive methods. Processes like CNC machining can produce a lot of leftover material.

Complexity Limits: The removal of material throughout the process generates more waste than additive processes. CNC machining, for example, might result in a large amount of excess material.

Setup Time and Cost: While CNC machines are fast and accurate, they require time to set up and program for new designs, especially for one-off or low-volume parts.

Subtractive vs. Additive Manufacturing

In recent years, the rise of additive manufacturing (3D printing) has prompted comparisons between the two approaches. So, how do they stack up?

Precision: Subtractive manufacturing generally offers higher precision and better surface finishes than 3D printing.

Material Options: Subtractive processes work with a broader range of materials, especially high-performance metals.

Waste: Additive manufacturing produces less material waste since it builds parts layer by layer.

Complexity: Additive manufacturing can produce more intricate internal geometries that may not be possible with subtractive methods.

Cost: For large-scale production runs, subtractive manufacturing is often more cost-effective, whereas additive methods shine for custom, low-volume parts.

Subtractive manufacturing is still an important part of today’s production, especially for industries that need high accuracy, flexibility with materials, and the ability to scale. While additive manufacturing (like 3D printing) is great for making complex, custom parts, subtractive methods such as CNC machining provide unmatched precision and smooth finishes.

Whether you’re prototyping a new design or producing thousands of parts for mass production, subtractive manufacturing provides a reliable and proven solution for your manufacturing needs. As the technology continues to evolve, its integration with other processes will only expand its capabilities, ensuring it remains a cornerstone of modern industry.

Do you want to learn more about subtractive manufacturing? Talk to an expert now, email us at info@hlhrapid.com or submit your CAD File here.

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Flame-retardant plastics are important for making products safer from fire in industries like electronics, automotive, and construction.

These special plastics help slow down or stop fires from starting. When combined with injection molding—a fast and efficient way to make plastic parts—flame-retardant plastics are used to create fire-safe products.

But what exactly happens during the injection molding process with these materials? Let’s look at the key points.

1. What Are Flame-Retardant Plastics?

Flame-retardant plastics are types of plastic that are specially treated to resist catching fire and slow down the spread of flames. These plastics are mixed with special chemicals that either stop the fire from starting or create a barrier to keep the fire from spreading. Some common flame-retardant additives include:

Halogenated compounds (chlorine, bromine)

Phosphorus-based compounds

Metal hydroxides(aluminum, magnesium)

Silicone-based flame retardants

Each type of additive offers different levels of effectiveness, safety, and environmental impact, influencing how the plastic will behave in various applications.

2.Why Use Injection Molding for Flame-Retardant Plastics?

Injection molding is a manufacturing process that allows for the high-volume production of plastic components with consistent precision and quality. For flame-retardant plastics, this process offers several advantages:

-Cost efficiency - Injection molding is ideal for large production runs, reducing costs per unit.

Design flexibility - Complex shapes and intricate designs can be easily produced.

Material efficiency - The process minimizes material waste, which is important when using expensive flame-retardant additives.

Additionally, injection molding ensures that the flame-retardant properties are uniformly distributed throughout the plastic component, which is crucial for meeting safety standards.

3.Processing Challenges with Flame-Retardant Plastics**

While injection molding offers many benefits, processing flame-retardant plastics comes with its own set of challenges. These include:

-High melt temperatures: Flame-retardant additives often require higher processing temperatures, which can lead to material degradation if not carefully controlled.

-Increased viscosity: Some flame-retardant additives make the plastic more viscous, affecting the flow during molding and potentially leading to defects like incomplete filling or surface marks.

-Wear on equipment: Certain additives, especially halogenated compounds, can be abrasive, causing wear and tear on molding equipment.

To overcome these challenges, manufacturers need to fine-tune their injection molding processes, including temperature control, mold design, and maintenance of the machinery.

4.Popular Flame-Retardant Plastics for Injection Molding

Different industries require different types of flame-retardant plastics depending on their application. Some of the most commonly used flame-retardant polymers in injection molding include:

ABS (Acrylonitrile Butadiene Styrene): Widely used in electronics and automotive components due to its good balance of toughness and flame resistance.

Polycarbonate: Known for its transparency and high impact resistance, polycarbonate is used in products like electrical housings and safety glasses.

Nylon (Polyamide): Common in automotive and industrial applications, flame-retardant nylon offers excellent mechanical strength and heat resistance.

PVC (Polyvinyl Chloride): Used in construction materials and electrical components, PVC is naturally flame-retardant but often enhanced for specific safety standards.

Each of these materials brings its own strengths to the table, depending on the specific needs of the product.

5.Applications and Industry Standards

Flame-retardant plastics are crucial in industries where fire safety is a priority. Some of the key applications include:

Electronics: Smartphones, laptops, and household appliances all rely on flame-retardant plastics to prevent electrical fires.

Automotive: Components like dashboards, connectors, and battery housings in electric vehicles require flame retardancy to meet safety regulations.

Construction: Building materials such as insulation panels, pipes, and electrical enclosures need to meet fire safety standards.

Products made from flame-retardant plastics must also comply with strict industry standards like **UL 94**, which tests for the flammability of plastic materials, and RoHS**, which regulates the use of hazardous substances, including certain flame-retardant additives.

6.The Future of Flame-Retardant Plastics in Injection Molding

As environmental concerns grow, there is a push toward more sustainable flame-retardant solutions. Traditional halogenated flame retardants, while effective, can be harmful to the environment and human health. This has led to the development of **halogen-free** flame retardants that are safer and more eco-friendly.

Additionally, advances in injection molding technology, such as **smart manufacturing** and **3D printing**, are enabling more precise control over the production process, leading to more efficient use of flame-retardant materials and reduced waste.

Injection molding of flame-retardant plastics is an important process for making safe products in industries where fire risks are a concern. Manufacturers need to choose the right additives and fine-tune the molding process to create high-quality, fire-resistant products. With new materials and technology, flame-retardant plastics are becoming more innovative and eco-friendly, helping improve fire safety standards in many industries.

Whether you're a manufacturer, designer, or a company who has questions related to injection moulding. Feel free to consult to us and upload your files here.  

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Everything You Need to Know About Bead Blast Finish in Rapid Prototyping

Rapid prototyping is a modern manufacturing method used to create physical models from digital designs.

Here’s a quick view of what is rapid prototyping:

By utilizing methods like 3D printing, CNC machining, or vacuum casting, it allows engineers and designers to transform CAD files into prototypes within hours or days. This process speeds up product development by allowing for repeated adjustments, testing, and improvements at a lower cost.

Rapid prototyping supports the evaluation of a product’s design, fit, and functionality before committing to full-scale production. It is widely used in industries such as aerospace, automotive, and consumer electronics to enhance innovation and reduce development time.

When it comes to rapid prototyping, choosing the right surface finish can make a big difference in the look and feel of your part. One popular option is the - bead blast finish, known for providing a smooth, matte surface. But what exactly is it, and why is it so commonly used in prototyping?

What is Bead Blast Finish?

Bead blasting is a surface treatment process that uses small, round particles (or "beads") to gently wear away the top layer of a material. The beads are typically made of glass, plastic, or metal, and they are blasted at the material's surface using high pressure. This results in a -matte finish, that is smooth to the touch, free from shiny spots or uneven textures.

In rapid prototyping, bead blasting is usually applied after parts are machined or 3D-printed to improve their appearance and feel.

Key Benefits of Bead Blast Finish

1. Smooth, Matte Surface: The main appeal of bead blasting is the sleek, non-reflective finish it provides. This can make parts look more professional and less rough compared to raw, untreated surfaces.

2. Removes Imperfections: Prototyped parts may have light imperfections or tool marks. Bead blasting helps to smooth out these blemishes, creating a more uniform surface.

3. Improves Grip: Bead blasting can also enhance the texture, providing a slight grip which is useful for prototypes of products that will be handled frequently.

4. Wide Material Compatibility: This finish can be applied to a variety of materials commonly used in prototyping, including metals like aluminum and steel, as well as plastics.

How is Bead Blasting Used in Rapid Prototyping?

After a prototype is made, whether by CNC machining, 3D printing, or injection molding, the surface may not always meet aesthetic or functional requirements. That’s where bead blasting comes in. Here's a simple breakdown of the process:

1. Preparation: The part is cleaned and prepared for blasting. Any delicate or critical areas may be masked off to prevent unnecessary wear.

2. Blasting: Beads are shot at the part’s surface at high pressure. The size and type of beads, as well as the pressure used, can be adjusted based on the material and desired outcome.

3. Post-Blast Finishing: Once blasting is done, the part is cleaned to remove any remaining media. Depending on the part’s purpose, additional finishes like anodizing or painting may be applied afterward.

In rapid prototyping, the bead blast finish is a valuable tool for creating smooth, attractive parts quickly and affordably. It’s a versatile method that works on various materials and can transform rough prototypes into presentation-ready products. Whether you’re working with metals or plastics, bead blasting is a finishing technique worth considering for your next prototype.

If you’re prototyping a part and want it to have that professional matte look, bead blasting could be the perfect finishing touch!

If you have questions about rapid prototyping or bead blasting, you may contact us at info@hlhrapid.com or simply submit your CAD file here: https://hlhrapid.com/instant-quote/

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How to Improve the Quality of Plastic Injection Molds?

Do you want to make high-quality plastic parts with injection molding? Curious about how mold quality impacts the final product? What can you do to ensure your molds give the best results? Let's check out the factors to improve the quality of your plastic injection molds.

Plastic injection moulding is a key method used to manufacture everything from little plastic parts to significant components. High-quality moulds are important for achieving the greatest outcomes. The quality of the mould has a direct influence on the finished product, from its appearance to its strength and durability. Here are some practical methods you may take to boost the quality of plastic injection moulds.

1. Choose the Right Material

The quality of your mould begins with the material you employ to create it. The mould material should be strong and resistant to damage, especially if you're making a big number of pieces. Hardened steel, stainless steel, and aluminium are examples of commonly used materials. Steel is more costly, but it has more durability and can generate higher-quality parts over time.

2. Design with Precision

A well-designed mould is necessary to deliver high-quality results. Pay particular attention to design elements like wall thickness, cooling channels, and draft angles. Proper design ensures that the plastic flows smoothly throughout the mould, lowering the possibility of flaws such as warping or partial filling. Use modern CAD (Computer-Aided Design) equipment to generate accurate and detailed designs.

3. Use High-Quality Injection Machines

The quality of the injection moulding machine has an important impact on the overall quality of the mould. Ensure that your machines are properly maintained and calibrated. Machines with upgraded controls can deliver more constant pressure and temperature, which are critical for making high-quality moulds.

4. Implement Rigorous Quality Control

Quality control is essential at every stage of the injection molding process. Regularly inspect molds for wear and tear and check the finished products for any defects. Using tools like Coordinate Measuring Machines (CMM) can help in accurately measuring parts and ensuring they meet specifications.

5.Optimize the Cooling Process

Cooling is a critical phase in injection molding that affects the quality of the final product. Uneven or inadequate cooling can lead to defects such as warping or shrinkage. To optimize cooling, ensure that the cooling channels in the mold are well-designed and that the coolant flows efficiently throughout the mold. Using conformal cooling techniques, where cooling channels are designed to follow the shape of the part, can further enhance the cooling efficiency.

6. Use Proper Mold Maintenance

Regular maintenance of molds is key to extending their life and ensuring consistent quality. Clean the mold regularly to remove any residues or buildup. Also, inspect the mold components like ejector pins and slides to ensure they are functioning properly. Lubricate moving parts to prevent wear and replace any worn-out components promptly.

 7. Control Injection Parameters

The parameters used during the injection process, such as temperature, pressure, and injection speed, significantly affect the quality of the molded parts. Fine-tuning these parameters can help reduce defects and improve overall product quality. Consider conducting trials to determine the optimal settings for your specific mold and material.

To improve the quality of plastic injection molds, use the right materials, design them accurately, use good machines, and maintain strict quality control. Regular maintenance and having skilled workers also help in making high-quality molds. By paying attention to these factors, you can produce parts that meet or exceed your quality expectations.

If you would like to discuss your requisites with one of our experts. You can submit you files here  and our team will contact you as soon as possible.

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Factors to Consider When Choosing Materials with CNC Rapid Prototyping

In this article, factors to consider in CNC Rapid Prototyping will be outlined to further assist businesses make the best decision for all the project needs.

When working on a new product, CNC fast prototyping is an excellent approach to quickly turn your ideas into actual products. This approach is popular among designers and engineers due to its precision, speed, and flexibility. However, one of the most important considerations you will have to make is which material to use for your prototype.

The material you choose might have a significant impact on the quality of your prototype.

1. What’s the Prototype For?

Before you begin selecting materials, you must first determine exactly what your prototype will be used for. Is it intended to be an operational version that can withstand pressure and testing, or is it only a visual model to showcase the design? The aim of your prototype will influence your material selection.

Working Prototypes: If your prototype needs to function like the final product, you’ll need strong, durable materials like aluminum or steel.

Visual Prototypes: If the prototype is just for looks, materials like ABS plastic or acrylic, which are easy to machine and look good, might be better.

2. How the Material Performs

Think about how the material will perform in your prototype. Here are some key factors:

Choosing materials that match your prototype’s needs will help ensure it works well in real life.

3.Ease of Machining and Cost

Not all materials are easy to machine, and this can affect both the quality of your prototype and how much it costs to make.

Ease of Machining: Some materials, like aluminum, are easy to work with and can be cut precisely with a smooth finish. Others, like harder metals or brittle plastics, might be more difficult to machine, which can increase costs and time.

Cost: Materials can vary greatly in price. While metals like titanium offer great performance, they are more expensive than alternatives like aluminum or plastic. Balancing cost with your project’s needs is crucial, especially if you’re on a budget.

4.Surface Finish and Post-Processing

The surface finish is especially important if your prototype needs to look good or fit together with other parts precisely.

Surface Finishing Requirements:  Some materials, such as acrylic or aluminium, can have an appealing surface directly off the CNC machine. Others may require further effort, such as sanding, polishing, or coating, to appear their finest.

Post-processing: Consider how the material will respond to subsequent treatments. Some materials may stretch or weaken during finishing operations, while others may improve with further stages.

5.Environmental Impact and Sustainability

Today, sustainability is more important than ever. When choosing materials, think about their environmental impact.

Recyclability: Using recyclable materials like aluminum and steel can help reduce waste and make your project more eco-friendly.

Material Source: Consider where the materials come from. Are they renewable, or do they require a lot of energy to produce? Choosing sustainable materials can help lower the environmental impact of your project.

6.Availability of Materials

Finally, think about how easy it is to get the materials you want. Some special materials might take longer to source or might not be readily available, which could slow down your project. Choosing materials that are easy to get can help keep your project on track.

Conclusion:

Choosing the right material is an important aspect of successful CNC fast prototyping. You could contribute to your project succeed by making sound choices based on the purpose of your prototype, the material's performance, ease of machining, cost, surface polish, environmental effect, and availability. Whether you're making an actual product or a visual mockup, choosing the correct material helps guarantee that your prototype accomplishes precisely what you want it to do.

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All You Need to Know About Sheet Metal Fabrication with HLH

Modern manufacturing relies largely on sheet metal fabrication, a process that turns plain metal sheets into complex parts and structures used in everything from consumer electronics to aircraft. Leading the industry in sheet metal fabrication, HLH combines modern technology with expert production to provide full solutions for customers.

Everything you need to know about using HLH for sheet metal manufacturing is provided here.

An Overview of Sheet Metal Fabrication:

The method includes bending, cutting, and assembling flat metal sheets into a variety of different parts. These components are necessary for industries like construction, electronics, automotive, and aerospace. Depending on the needs of the application, the manufacturing procedure usually begins with a sheet of metal, which can be aluminum, steel, copper, or another alloy.

The fabrication process includes several steps:

 Sheet Metal Fabrication Process         

Design and Planning:  CAD Modeling, Material Selection         

Cutting: Shearing, Laser Cutting, Plasma Cutting & Waterjet Cutting 

Forming: Bending, Stamping, Rolling, Embossing         

Joining: Welding, Riveting, Adhesive Bonding & Fastening        

Finishing: Deburring, Polishing,Painting or Powder Coating, & Anodizing          

Inspection/Quality Control: Dimensional Inspection, Material Testing, Functional Testing

Assembly: Final Assembly & Functional Testing            

HLH’s Expertise in Sheet Metal Fabrication

HLH has established itself as a trusted manufacturing company for sheet metal fabrication, providing a complete range of services customized for each project. Here's what makes HLH stand out in the industry:

HLH Rapid is a leading company in sheet metal fabrication. The company achieve this by using modern equipment such as high-precision laser cutters and CNC press brakes, which allow them to create complex parts with precise measurements and reliable quality.

HLH Rapid has vast experience with various metals, including copper, stainless steel, aluminium, and speciality alloys, allows them to select the ideal material for any application while keeping cost, weight, and strength in mind.

The company provides flexible manufacturing as well as rapid prototyping, enabling prompt turnarounds and effective large-scale runs while upholding high standards through strict requirements and inspections at every point. We also provide customisable assembly procedures, specialised finishes, and custom tooling, all of which are catered to the particular needs of each client.

Conclusion:

Sheet metal fabrication is a critical process in modern manufacturing, enabling the production of a wide range of components across various industries. We have the capabilities to deliver high-quality, customized solutions that meet your specific needs.

By choosing HLH for your sheet metal fabrication projects, you’re ensuring that you receive precision, reliability, and excellence every step of the way.

If you would like to discuss your requisites, please send us an email at info@hlhrapid.com or upload your CAD file here to get an instant quote.

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CNC Machining vs. Additive Manufacturing: Understanding the Key Differences

In today's manufacturing world, CNC machining and additive manufacturing are two key methods that serve different production needs. Each has its own strengths and weaknesses, so it's important to know how they differ to make the best choices in manufacturing.

This blog explains the main differences between CNC machining and additive manufacturing, focusing on their benefits and uses.

CNC Machining: Precision Through Subtraction

Overview:

CNC machining is a traditional manufacturing method that involves the precise removal of material from a solid block using computer-controlled tools. This subtractive process utilizes rotary cutters, drills, and mills to achieve the desired shape and dimensions.

Materials and Techniques:

CNC machining is compatible with a broad range of materials, including metals (such as aluminum, steel, and titanium), plastics, and composites. The process is renowned for its ability to produce high-precision components with tight tolerances, making it ideal for applications that demand rigorous accuracy, such as aerospace, automotive, and medical industries.

Advantages:

High Precision: CNC machining excels in producing parts with tight tolerances and detailed specifications.

Material Versatility: Capable of working with a variety of materials, including high-strength metals and complex composites.

Consistency: Once set up, CNC machines can produce consistent results across large production runs.

Limitations:

Waste Generation: As a subtractive process, CNC machining can result in significant material waste, impacting overall efficiency and cost.

Setup Time: The initial setup for CNC machining can be time-consuming and costly, particularly for complex or custom parts.

Additive Manufacturing: Innovation Through Addition

Overview:

Additive manufacturing, commonly known as 3D printing, is a cutting-edge technology that builds objects layer by layer from a digital model. This additive process allows for the creation of complex geometries and intricate designs that are challenging to achieve with traditional methods.

Materials and Techniques:

Additive manufacturing supports a diverse range of materials, including thermoplastics, resins, metal powders, and even bio-materials. Technologies such as FDM (Fused Deposition Modeling), SLA (Stereolithography), and SLM (Selective Laser Melting) enable the production of parts with varying degrees of complexity and material properties.

Advantages:

Design Flexibility: Capable of producing highly complex and customized parts with intricate internal structures.

Rapid Prototyping: Ideal for quick prototyping and low-volume production, allowing for rapid iterations and design changes.

Material Efficiency: Minimizes material waste by using only the necessary amount of material to build the part.

Limitations:

Production Speed: Additive manufacturing can be slower for large-scale production compared to traditional methods.

Precision Variability: While precise, the level of detail may vary depending on the technology and material used.

Comparative Analysis

1. Production Process

CNC Machining: Subtractive process that removes material from a solid block to achieve the final shape.

Additive Manufacturing: Additive process that builds up layers of material to form the final part.

2. Material Handling

CNC Machining: Effective with a range of solid materials, including metals and plastics.

Additive Manufacturing: Utilizes a variety of raw materials, including powders and filaments, suitable for complex designs.

3. Precision and Tolerance

CNC Machining: Known for high precision and tight tolerances, suitable for detailed and exact specifications.

Additive Manufacturing: Offers design flexibility with varying precision depending on the technology and material.

4. Production Volume and Speed

CNC Machining: Efficient for medium to high-volume production, though initial setup can be time-consuming.

Additive Manufacturing: Excels in low-volume production and rapid prototyping, but may be less efficient for large-scale manufacturing.

5. Environmental Impact

CNC Machining: Can generate material waste due to the subtractive nature of the process.

Additive Manufacturing: More material-efficient with minimal waste, supporting sustainable manufacturing practices.

CNC machining and additive manufacturing are both useful options for any kind of production demands. CNC machining is still a popular alternative for high-precision, high-volume production, but additive printing offers unique flexibility for complicated and customised items. Understanding these differences allows manufacturers to choose the best technology for a given project, material requirements, and production goals.

In many circumstances, combining the two methods may take use of their individual strengths, delivering a holistic solution to current production difficulties. Businesses may improve their production processes and promote development in their respective industries by carefully evaluating the different features of CNC machining and additive manufacturing. To get an instant quote, upload your file here: https://hlhrapid.com/instant-quote/

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How CNC Machining Supports Customization of Automotive Parts?

In automotive design and manufacturing, customization is very important. Whether you want to improve a car's performance, change its look, or make it stand out, CNC machining is a great method for customizing car parts.

But what is CNC machining, and how does it help with customization? Let’s explain it in simple terms.

What is CNC Machining?

CNC stands for Computer Numerical Control. It’s a technology that uses computers to control machines that cut, shape, and finish materials. In CNC machining, a computer program directs a machine to perform precise cutting tasks on materials like metal, plastic, and wood. This allows for incredibly accurate and complex shapes to be made, which is essential for customizing automotive parts.

Precision and Accuracy

One of the biggest advantages of CNC machining is its precision. When you want to customize a part of your car, such as a new intake manifold or custom wheels, the parts need to fit perfectly. CNC machines can create parts with extremely tight tolerances, meaning the parts will be exactly as designed. This precision ensures that all customized parts fit perfectly and function as intended.

Creating Complex Designs

Cars often need parts with intricate designs. For example, you might want a custom grille or a specialized bracket for a performance upgrade. CNC machining can handle these complex designs with ease. The computer controls allow the machine to make detailed cuts and shapes that would be very difficult or impossible to achieve by hand. This means that custom designs can be brought to life with high accuracy.

Speed and Efficiency

CNC machines are fast. Once a design is programmed into the computer, the machine can produce parts quickly and consistently. This is especially useful when you need multiple parts, such as for a limited edition vehicle or a small batch of custom accessories. CNC machining can produce these parts faster than traditional methods, saving time and making the customization process more efficient.

Flexibility in Design Changes

Sometimes, a design needs to be adjusted or refined. With CNC machining, making changes to a part’s design is relatively easy. Since the design is controlled by a computer program, you can quickly update the program to reflect any changes. This flexibility means you can experiment with different designs and make adjustments without having to start from scratch each time.

High-Quality Finishes

Custom automotive parts often require a high-quality finish to look great and perform well. CNC machining can achieve smooth, precise finishes on a variety of materials. Whether it’s a custom aluminum wheel or a carbon fiber component, CNC machines can provide the surface quality needed for both functional and aesthetic purposes. This ensures that custom parts not only fit well but also look polished and professional.

Cost-Effective Customization

Although CNC machining may seem expensive at first, it can be cost-effective in the long run. For custom parts, the cost of setting up the machine and programming can be offset by the precision and efficiency of the machining process. Additionally, CNC machining reduces waste material, which helps keep costs down. For custom parts that need to be produced in small quantities, CNC machining can be a cost-effective solution.

Supporting Innovation

The automotive industry is constantly evolving, with new technologies and designs emerging all the time. CNC machining supports innovation by allowing designers and engineers to create and test new ideas quickly. Whether it’s a new engine component, a unique body part, or an innovative accessory, CNC machining provides the flexibility and precision needed to explore and implement new concepts.

In Summary

CNC machining is really important for customizing car parts. It's precise, can handle complex designs, works quickly, and is flexible, making it perfect for creating custom parts. Whether you want to boost your car's performance or change its look, CNC machining can help make your ideas a reality with accuracy and speed. Knowing how to use CNC machining can help you get the best results when customizing your car.

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What Is CNC Prototype Machining and When To Use It?

When you need to order detailed and functional prototypes for a product or part, CNC prototype machining is a tried-and-true process that may suit your project perfectly. In this article, we will take a deeper look into the CNC prototype machining process, its advantages and applications, how it compares to other rapid prototyping technologies, and how to progress from CNC prototypes to full-fledged CNC production.

What is CNC Prototype Machining

CNC prototype machining is a subtractive manufacturing process whereby physical prototypes or products models are made using computer numerical control (CNC) machines. These machines are programmed to precisely and automatically shape and cut materials, such as metal and plastics based on digital design specifications. This is known as a subtractive process, meaning the prototype is made by cutting material away.

CNC machines work based on a pre-uploaded file called a CAD file, which only the computer can read. In other words, there is close to no human involvement in the production process. This makes CNC prototype machining one of the most reliable ways to make prototypes due to its speed and incomparable accuracy that allows engineers and designers to test and validate their designs before moving on to full-scale production.

Advantages of CNC Prototype Machining

As you may or may not already know, you have many options when it comes to manufacturing prototypes. Why use CNC for prototypes? In answer, here are 5 advantages that make CNC prototype machining so attractive among product engineers and designers.

1. Yields Fast Turnaround Time

CNC machining offers rapid prototyping, which means that prototypes can be created relatively quickly compared to traditional machining methods. This allows for faster design iterations and a shorter time to market.

2. Highly Repeatable

Since CNC machines are operated by a computer, it produce prototypes with a high degree of consistency. This repeatability ensures that multiple prototypes will be virtually identical, making it easier to evaluate and refine the design.

3. Very Precise

Another reason that CNC is so popular for prototypes is how it produces precise prototypes with high tolerance specifications. This means that the prototype can be extremely detailed – almost to the point that it is just as (or nearly) detailed as the final end use part.

4. Available in a Wide Range of Materials

With CNC prototype machining, you’re not limited to certain types of material. Your parts can be machined from a wide range of plastics as well as metals, including copper, aluminium, and stainless steel. This flexibility in material choice allows designers to experiment with different materials to find the most suitable one for their final product.

5. Suitable for Complex Geometry

CNC machines excel at creating prototypes with intricate and complex designs. They can handle three-dimensional shapes and intricate details with ease, which is especially valuable for industries like aerospace, automotive, and medical devices.

When To Use CNC Prototype Machining (+ Applications)

CNC prototype machining is a versatile and valuable tool in various industries for creating prototypes and models. It is typically used when:

Testing New Product Designs: CNC prototype machining is ideal for testing and validating new product designs. It allows designers and engineers to create physical models quickly and accurately to assess not just the appearance but also form, fit and function.

Iterative Development: When a design needs multiple iterations and refinements, CNC machining can produce prototypes rapidly, facilitating the testing and refinement process.

Material Evaluation: It is used to test and evaluate different materials to determine their suitability for a particular application. This is valuable for selecting the best materials for the final product.

Low-Volume Production: For low-volume production runs, CNC prototype machining is cost-effective and efficient, offering a viable alternative to traditional manufacturing methods.

Applications of CNC prototype machining are widespread and include:

Medical: It goes without saying that the medical industry needs tools and equipment that are as precise and flawless as possible. Lives literally depend on their proper function. CNC machining offers the accuracy needed to properly demonstrate how new innovations will work in this field via prototypes.

Automotive: CNC prototype machining can help automotive companies test parts that will contribute to the functionality (and more importantly, the safety) of new vehicles.

Aerospace: Just as in automotive, precision is key in the aerospace industry. One small deviation or flaw could cause ripple effects that compromise entire aircraft, making it dangerous for them to be used. CNC machining is accurate enough that aerospace engineers rely on it to make manifolds, parts for landing gear, and other essential aircraft components.

Consumer Electronics: Prototyping for gadgets, mobile devices, and other consumer electronics to test their functionality and aesthetics.

Oil & Gas: CNC machines are often responsible for producing parts for the oil and gas industry, including drill bits, spacers, hydraulics, and more. You’ll also find CNC prototype machining used in the military industry, and to produce electronics.

CNC Prototype Machining Vs 3D Printing

When thinking of prototyping technologies, you will often across different methods CNC machining and 3D printing. CNC prototype machining and 3D printing are two distinct but complementary technologies in the realm of rapid prototyping and product development.

3D printing is additive, meaning it produces prototypes or parts by printing them layer by layer. Meanwhile, CNC machining is subtractive. Essentially, it carves the prototype out of raw material by removing sections of the material that don’t fit with the desired design.

Because 3D printing is an additive process, it allows for the creation of more intricate and complex geometries that would otherwise be challenging or impossible to achieve through traditional subtractive methods. For this reason, it also allows for minimal material waste, as it only uses the exact amount of material required for the model.

In contrast, due to its subtractive nature, CNC prototype machining is ideal for achieving extremely precise and accurate prototypes that often cannot be achieved with 3D printing technologies.

Selecting between 3D printing and CNC machining hinges on the project’s unique demands. 3D printing shines when swift creation of intricate designs is essential, while CNC machining stands out for its unrivaled precision and robustness, particularly in conventional or material-intensive applications. Frequently, engineers and designers synergize these two technologies to craft diverse components, enabling a comprehensive optimization of their prototypes.

From CNC Prototypes To CNC Production

One of the biggest benefit of using CNC prototype machining is the pipeline to production. In most cases, prototypes are produced close to the end of the ideation phase, right before mass production of the final product begins. CNC machining can produce highly accurate prototypes that are just as functional as the end use part. They can even be made of the same materials.

This means that once the prototype has been approved, it is a simple matter to go straight into production of the end use part. Thus, the pipeline from CNC prototype to CNC production is natural and quick.

Now that you’re confident in the knowledge of how CNC prototype machining works and when it’s best used, we encourage you to contact an expert at HLH Rapid and get a quote on your next prototyping project.

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Most Popular Tooling Materials in Injection Moulding and Their Typical Tool Life

When it comes to injection moulding, the mould tool is the most critical and costly component in the process. There are many tooling material options to choose from: aluminium, soft and semi-hardened steel, and hardened steel. While mould makers like HLH can assist you in choosing a suitable tooling material for your project, it’s worth gaining a basic foundation and understanding your options to avoid costly errors, waste, and defects down the road.

In this article, we will look at the most popular steel and aluminium tooling options available for plastic injection moulding, their typical tool life, the pros and cons of each, and scenarios in which each is best to use.

Popular Tooling Material Options for Injection Moulding

Aluminium

S50C

P20

NAK80

H12

S136

1. Aluminium

Aluminium (AL) is often used as a quick and lower-cost alternative to steel tooling. AL has good machinability and excellent heat transfer properties (cools quickly and efficiently), which makes it a good option for prototyping and low-volume production runs. A main drawback is that the tooling life is generally shorter, and not all grades of plastics are suited for aluminium tooling; for instance, materials that require high mould temperatures.

Soft tooling option.

Commonly used for prototype and low-volume tooling — with an average life of 10,000 shots depending on the grade and part complexity.

Easy to machine and offers excellent turnaround times.

Less durable than steel tooling and not suited to plastics that require high mould temperatures like polyetherimide (PEI), polyether ether ketone (PEEK) or polysulfone (PSU).

2. S50C

S50C is a ‘soft’ steel option that is especially popular in China for prototype tooling. It is a great for general applications and a good alternative to aluminium. However, if the part material or surface finish calls for a hardier tool, P20 steel is used.

Soft steel.

Commonly used for rapid tooling tooling applications — with an average life of 50,000 shots or less depending on the grade and part complexity.

Less expensive than P20 steel.

Less durable than P20 and not suitable for materials with abrasive additives.

Pro Tip: You can often get Chinese tools like S50C and P20 at the price of an aluminium tool. Most Chinese tool shops prefer working with steel tools for rapid tooling because they are harder, more robust, and easier to weld.

3. P20

P20 is a ‘soft’ steel often used as a standard steel tooling option and is the first choice for materials without abrasive additives. For prototype or development tooling, P20 steel offers several advantages over aluminium: it is stronger, more durable and offers a longer tool life; it is less costly; and it is generally more resistant to scratching than aluminium. A main drawback is that P20 is not very resistant to erosion or chemical corrosion, which can impact its tool life.

Soft steel.

Commonly used for prototype tooling and intermediate quantities — with an average life of 50,000 cycles or more, depending on the part’s geometry and tolerances.

P20 is harder and more durable than aluminium, with approximately a 5x longer tooling life.

May require coatings or surface treatment to protect against corrosion and erosion.

P20 Application Case Study: HLH Rapid Uses P20 Steel Tool For SOL Reader’s E-Ink Glasses.

 4. NAK80

NAK80 is a semi-hardened tool steel typically used for more demanding applications. NAK80 is typically used for higher quality parts and transparent and high-gloss components. It also works better with resins with glass fibers or hard, engineering-grade plastics like Delrin or Aceral (POM). Although it’s more corrosion resistant than P20, one key drawback is that it takes longer to machine.

Hardened steel.

Commonly used for bridge tooling and production tooling — with a typical tool life of 300,000 to 500,000 shots.

NAK80 takes polishing well, and produces optically clear and high glossy parts.

Costs more than P20 steel tool and typically takes 20-25% longer to produce.

5. H13

H13 is a ‘strong’ steel that is robust and have exceptional resistant to heat. It is most commonly used for high production quantity tooling and to address wear when running abrasive materials. H13 also works well for materials that require high tool temperatures like polyamide-imide (PAI), PEEK, and liquid crystal polymer (LCP).

Strong steel.

Commonly used for high volume runs of several hundred thousand to 1 million cycles.

H13 is best for aggressive resins and optical parts made of clear plastic like acrylic (PMMA) or polycarbonate (PC).

More expensive than P20 and NAK80 steel.

6. S136

S136 is stainless steel that offers excellent hardness and is mainly used for speciality cases in high production tooling. It has good corrosion resistance, which makes it good for corrosive environments or materials such as polyvinyl chloride (PVC) and polypropylene (PP). It also has excellent polishability and is a good choice for large-size precision parts. The main drawback is that S136 costs the most and has the lowest thermal efficiency, so unless you require a high production run, it may not financially make sense.

Hard stainless steel.

Commonly used for high volume runs of 1 million or more.

S136 is best for corrosive plastic materials like PVC and PP.

Most expensive steel tooling option among the five options.

Other Tooling Material Options

Above, we’ve listed the 5 most commonly used aluminium and steel tooling material options for injection moulding projects, however, there are many other tool material options for special cases and applications. Check them out in the list below.

A2 tool steel

718

718H

738

738H

S7

S50C

SS420

STAVAX 48-52HRC

SKD61

1.2083

1.2343

1.2344

1.2738H

2083H

2083 HRC48-52

2344 (HRC48-52)

2738

Custom tooling & injection moulding

Submit CAD, get a quote within 24-48 hours or less

Get a quote now

The Typical Tooling Game Plan at HLH

Typically, our clients begin with single-cavity S50C or P20 steel tools for prototyping and developmental applications—S50C for our rapid tools and P20 if the part material or surface finish calls for a hardier tool. For applications requiring engineer-grade or glass fibre resins, or for moulds necessitating a higher level of polishing, NAK80 steel is preferred.

Often, for niche market or specialized products, P20 or NAK80 steels may be all the client needs to satisfy demand. These steels require a lower investment than full production tooling, helping customers minimize costs in the early stages and get initial products to market faster.

If the product demand is high and where it makes sense, customers may move on to H13 or other hardened steel, production multi-cavity tooling.

Fast Tooling & Injection Moulding With HLH Rapid

At HLH, we make prototype tooling, bridge tooling and production tooling in-house for simple to complex injection moulding projects. If you are unsure what tooling material to go for, get in touch with our engineering team at info@hlhrapid.com.

To get started on your next injection moulding project, simply submit your 3D CAD along with any project details like material, surface finish or quantity, to our contact form. Our team will get back with a quote within 24 to 48 hours or less.

Visit our website: https://hlhrapid.com/blog/injection-mould-tooling-material-steel-and-aluminium-tools/

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The Benefits of Using Carbon Steel in CNC Machining: A Technical Perspective

CNC machining is currently the most widely used in modern manufacturing, making it possible to create detailed and accurate parts. Carbon steel is one of the popular materials used in this process because of its great properties and flexibility. In this blog post, we will look at the technical advantages of using carbon steel in CNC machining and why many industries prefer it.

Here are the highlights of using Carbon Steel in CNC Machining:

Mechanical Properties and Strength

Carbon steel is well-known for its great mechanical properties, making it perfect for CNC machining. Its high tensile strength means parts can handle a lot of stress and load without bending or breaking. This strength is especially important in industries like automotive and aerospace, where parts face heavy forces.

        Yield Strength and Hardness

Low Carbon Steel (up to 0.3% carbon): This steel is moderately strong and easy to machine, making it good for parts like brackets and fasteners that don't need high hardness.

Medium Carbon Steel (0.3% to 0.6% carbon): This type of steel balances strength and flexibility. It's often used for gears, axles, and other parts that need more hardness than low carbon steel.

High Carbon Steel (0.6% to 1.0% carbon): This steel is very hard and resistant to wear, making it ideal for cutting tools and dies.

Machinability and Precision

The machinability of a material is a critical factor in CNC machining. Carbon steel exhibits excellent machinability, which allows for the efficient and precise manufacturing of complex parts. This property is influenced by the carbon content and the presence of other alloying elements.

Cutting Speeds and Feed Rates

Optimal Cutting Conditions: Carbon steel can be machined at high cutting speeds and feed rates, which enhances productivity. For example, low carbon steel can be machined at cutting speeds up to 300 feet per minute (fpm), while high carbon steel may require slower speeds around 150 fpm to prevent tool wear.

Tool Life: The material's machinability helps extend the life of cutting tools by reducing wear and tear, which is critical for maintaining tight tolerances and surface finishes.

Heat Treatment and Customizability

One of the standout features of carbon steel is its ability to undergo various heat treatment processes to alter its mechanical properties. Heat treatment techniques such as quenching, tempering, and annealing can significantly enhance the hardness, strength, and toughness of carbon steel parts.

Heat Treatment Processes

Quenching and Tempering: Increases hardness and strength by rapidly cooling the material after heating, followed by reheating to a specific temperature to achieve the desired toughness.

Annealing: Softens the material, improving its machinability and making it easier to form and cut.

These processes let you adjust carbon steel’s properties to fit different needs, making it a flexible material for CNC machining.

 Cost-Effectiveness and Availability

Carbon steel is easy to find and cheaper than metals like stainless steel or titanium. Its low cost makes it a good choice for manufacturers who want to balance performance and budget. Because it’s widely available, there’s always a steady supply, which helps reduce lead times and supports large-scale production.

Material Grades and Standards

-ASTM Standards: Carbon steel grades are standardized by organizations such as ASTM (American Society for Testing and Materials), ensuring consistent quality and properties across different batches.

-Cost-Effective Production: The lower cost of carbon steel raw materials contributes to the overall cost-effectiveness of CNC machined parts.

Corrosion Resistance

Carbon steel doesn’t resist corrosion on its own, but coatings and finishes can make it more durable. Techniques like galvanizing, powder coating, and painting create a protective layer that stops rust and corrosion.

Protective Coatings

Galvanizing: Involves applying a zinc coating to the steel, offering excellent corrosion resistance and extending the lifespan of the parts.

Powder Coating: Provides a durable, aesthetically pleasing finish that also improves corrosion resistance.

In conclusion, carbon steel is great for CNC machining and is widely used in many industries. Its strong mechanical properties, easy machinability, customizability with heat treatment, cost-effectiveness, and potential for better corrosion resistance make it popular in automotive, aerospace, and construction.

Using carbon steel, manufacturers can create high-quality, reliable, and affordable parts that meet modern engineering and manufacturing needs. If you would like to discuss more about Carbon Steel using CNC Machining, feel free to reach us at info@hlhrapid.com our submit your CAD file here to get an Instant Quote.

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Top Reasons to Use CNC for Rapid Prototyping in various industries

Modern product development places great emphasis on rapid prototyping, allowing industries to innovate, make adjustments, and expedite the process of bringing products to market. CNC machining is widely preferred for this purpose and is highly suitable for rapid prototyping across different industries.

1.Aerospace Industry

Precision and Accuracy:

In the aerospace sector, precision is critical, and CNC machines are important in guaranteeing that each prototype satisfies particular specifications. For parts to be produced that can resist high stress levels and difficult climatic conditions, accuracy is crucial.

Complex Shapes:

Many parts for aircraft are made with complicated patterns and complex forms. Prototypes that nearly match the finished product may be produced because to CNC machines' ability to manage these  complexity with ease.

2.Automotive Industry

Speed and Efficiency:

The rapid pace of innovation is essential in the automotive industry. High-quality prototypes can be quickly produced using CNC machining, reducing the time required to go from concept to physical model. Engineers can efficiently test and enhance designs due to this speedy turnaround.

Material Variety:

CNC machines can handle a variety of materials, including metals and polymers, which are commonly used in car components. This versatility makes it easier to create realistic prototypes that closely resemble the finished product.

3.Medical Devices

Smooth Finishes:

Medical instruments require smooth, high-quality surfaces for safety and operation. Because it produces excellent finishes, CNC machining is suitable for developing medical device prototypes that fulfil high criteria.

Easy Changes:

Developing medical devices often involves many design changes. CNC machining allows for quick and easy modifications, speeding up improvements and refinements.

4.Consumer Electronics

Complex Designs:

Consumer electronics often have compact and intricate designs. CNC machines excel at creating detailed prototypes with precise shapes, ensuring that every component fits perfectly.

Scalability:

Once a prototype is finalized, CNC machining can easily produce multiple units with consistent quality. This scalability is great for electronics companies moving from prototypes to small-scale production.

5.Architecture and Construction

Material Flexibility:

CNC machines can work with a variety of materials like wood, plastics, and composites. This flexibility is useful in architecture and construction, where prototypes might involve different materials to accurately represent the final structure.

Cost-Effective:

CNC machining cuts down the need for expensive molds and tools, making it a cost-effective choice for creating architectural models and construction prototypes.

6.Fashion and Jewelry

Detailed Designs:

In fashion and jewelry, intricate designs and fine details are essential. CNC machining provides the precision needed to create detailed prototypes of jewelry pieces and fashion accessories.

High-Quality Finishes:

High-quality finishes are crucial in these industries. CNC machining ensures that prototypes not only look professional but also meet the high standards expected by consumers.

CNC machining offers many benefits for rapid prototyping in various industries. From the precision needed in aerospace and medical devices to the speed and efficiency required in automotive and consumer electronics, CNC technology is a versatile and reliable solution. Its ability to handle complex designs, work with different materials, and produce high-quality finishes makes it an invaluable tool in the prototyping process. By using CNC machining, companies can streamline product development, innovate faster, and bring new products to market more efficiently.

If you would like to discuss your requisites with our experts, submit your CAD files here or send us an email at info@hlhrapid.com