Product 1 – USB A Male Outer Film Mold  
Product Name: USB A Male Outer Film  

The USB A male outer film is a critical molded component widely used in data cables, charging cables, and other consumer electronics connection products. Product 1 – USB A Male Outer Film is designed as a specialized mold solution that focuses on precision, stability, and long‑term durability, making it suitable for large‑scale and repeatable production of USB A connectors. This component is typically used as the outer protective layer around the metal USB A plug, enhancing mechanical strength, improving appearance, and providing insulation and strain relief for the internal conductors.

This product belongs to the category of plug mold / wire mold / twisted tooth mold / material saving mold / hot runner system mold. In practical applications, the tool can flexibly adopt different mold configurations according to the project requirements. As a plug mold, it is directly used to encapsulate and form the USB A male plug structure. As a wire mold, it is suitable for molding the joint area where the USB A plug and cable are connected. In addition, the twisted tooth mold structure helps to stabilize the internal metal terminal and enhance retention. The material saving mold and hot runner system mold design reflect an emphasis on production efficiency and cost optimization, making this product suitable for both medium and high‑volume manufacturing.

Material and Surface Treatment  

The main mold material chosen for Product 1 – USB A male outer film is SKD11. SKD11 is a high‑carbon high‑chromium alloy tool steel known for its excellent wear resistance, high hardness, and dimensional stability. These characteristics are especially important for molds that need to withstand frequent opening and closing, repeated injection cycles, and contact with plastic materials under high pressure and temperature. In the context of USB A male outer film molding, the dimensional accuracy of the cavity directly affects the fit between the plug shell and the internal metal components, so the stability of SKD11 after heat treatment plays a crucial role in maintaining product consistency.

The surface treatment process adopted is heat treatment. Through proper hardening and tempering processes, the SKD11 mold steel can reach an appropriate hardness range, balancing wear resistance with toughness to reduce the risk of cracking or deformation in long‑term use. Heat treatment also helps improve the surface fatigue resistance of the mold, which is beneficial when the same mold is expected to run up to hundreds of thousands of cycles without obvious degradation. A well‑executed heat treatment process ensures the cavity can maintain high precision even after extended operation, so the USB A male outer film products remain consistent in dimension, surface finish, and assembly performance.

Mold Frame and Structural Features  

The mold frame material is S45, a commonly used medium‑carbon structural steel. S45 provides adequate strength and toughness for supporting the core and cavity inserts made from SKD11. Using SKD11 for the wear‑critical forming areas and S45 for the main supporting frame strikes a cost‑effective balance between durability and economic efficiency. This structure ensures that the mold can withstand clamping force, injection pressure, and repeated mechanical loads during operation.

The mold lifespan is specified as 300,000 times. Within this specification, the mold is expected to maintain reliable performance, stable dimensional accuracy, and acceptable surface quality of molded parts throughout these cycles. A 300,000‑shot lifespan is well suited to many consumer electronics and accessory products, where mid‑ to high‑volume production is often required but may not always extend into multi‑million shot ranges. With appropriate maintenance, cleaning, and periodic inspection, the effective service life can in practice be further prolonged.

Chamber and Plastic Material  

The chamber is designed to be compatible with TPE/PVC. TPE (thermoplastic elastomer) offers flexibility, elasticity, and a soft‑touch surface, making it suitable for protecting the cable outlet of the USB A connector and improving hand feel. PVC (polyvinyl chloride) is widely used in wire and cable applications due to its good insulation properties, flame retardancy (in certain formulations), and cost‑effectiveness. Designing the chamber for both TPE and PVC means the mold can support various product lines and different performance levels, such as soft high‑flex cables, standard charging cables, or more rigid, durable data cables.

The plastic material injection process is described as bilateral glue injection. Bilateral glue injection indicates that the plastic is injected symmetrically from two sides or in a way that ensures the outer film is evenly encapsulated on both sides of the USB A male connector. This method is especially important for flat wire structures or cables where bilateral symmetry is required for mechanical balance and appearance aesthetics. Bilateral injection can reduce the risk of warpage and uneven shrinkage, helping maintain a straight and uniform cable outlet.

Gate Type and Channel Type  

The gate type is specified as a combination of cold and hot aisle. The cold and hot aisle arrangement combines hot runner technology with cold runner feed or sub‑gate systems. A hot runner system mold reduces material waste in the runner area and improves flow balance, while the cold runner section allows more flexible gate positioning or a simpler final part separation process. This hybrid system is often used when trying to balance mold cost, production flexibility, and material utilization efficiency.

The channel type is described as 45 days. In a typical context, this may refer to a specified design or internal production standard related to the channel configuration and flow path layout, tightly linked with the lead time and engineering cycle. It may also indicate that the studied and optimized runner channel structure can support a 45‑day delivery time target from order confirmation to mold shipment. For users, this data implies the mold can be engineered, manufactured, and prepared for trial production within a relatively short project timeline, which is critical for rapidly changing consumer electronics markets.

Delivery Time and Wire Structure  

The delivery time is defined together with the specification: flat wire 1.8 mm × 4.5 mm. The mold is tailored to support flat wire products with a cross‑section of 1.8 mm thickness and 4.5 mm width. Flat wire cables are widely used in modern electronics due to their compact profile, good bending performance, and neat appearance, often seen in charging cables, data transfer cables, or integrated interface cables for portable devices.  

The wire diameter range is also given as flat wire 1.8 mm × 4.5 mm, indicating that the mold is optimized for this specific flat cable size. All related structures, such as the cable channel, clamping area, and strain relief shape, are designed around this range. This greatly improves the fit between the molded USB A male outer film and the cable, ensuring that the product can achieve firm clamping, effective strain relief, and good sealing performance.

Outlet Hole Size and Draft Angle  

The outlet hole size is 3.5 mm. This dimension is crucial for matching the outgoing cable cross‑section and allowing for appropriate compression or grip. An outlet hole slightly smaller than the maximum cable dimension can create a tight fit, enhancing strain relief and preventing the cable from being easily pulled out. However, this needs to be carefully balanced to avoid excessive stress on the cable jacket, especially when using TPE or PVC, which have different hardness and flexibility levels.

The draft angle is left unspecified, allowing flexible adjustment depending on the actual production requirements, part geometry, and surface finish. In production practice, a small draft angle (for example 0.5–1.5 degrees) is typically applied to eject the part smoothly without affecting the connection accuracy of the USB A plug area. When designing for TPE or PVC, the draft angle can also be tailored to their shrinkage behavior and the required retention on the core.

Mold Size, Cavities, and Layout  

The overall mold size is 200 mm × 150 mm × 15 mm. This compact mold dimension indicates a relatively small mold footprint, which is suitable for installation in standard injection molding machines with moderate clamping force. The small‑scale design is particularly advantageous when multiple molds are run on different machines in parallel, or when frequent mold changes are needed to produce various models of connectors.  

The number of mold cavities is four. A four‑cavity layout increases productivity compared with a single‑cavity mold while maintaining manageable complexity in runner design and filling balance. With four cavities, each injection cycle produces four USB A male outer film parts, effectively reducing cycle cost and improving capacity. The runner and gate design in conjunction with the cold and hot aisle system must ensure that each cavity fills evenly, with minimal pressure difference and stable cooling, so all four parts display similar mechanical properties and appearance.

Original and 3D Images  

Original and 3D images are referenced as part of the design information. While not displayed here, in a typical development process, original 2D drawings define the exact dimensions, tolerances, and functional requirements of the USB A male outer film, while 3D images (such as CAD models) support mold flow analysis, structural simulation, and visual inspection of assembly relationships. These 3D models are essential for verifying the alignment between the USB metal insert, cable, and outer film, ensuring that the final product meets mechanical, electrical, and aesthetic expectations.

Application and Performance Overview  

Product 1 – USB A male outer film mold is suitable for a wide range of consumer electronics, communication equipment, and peripheral accessories. Typical applications include:  

1. USB charging cables for phones, tablets, and portable devices.  
2. Data cables for interfacing external hard drives, keyboards, mice, and other peripherals.  
3. Customized flat wire USB cables used in tight spaces or integrated wiring harnesses.  

By combining SKD11 for the core and cavity, S45 for the mold frame, heat treatment for durability, and a four‑cavity, cold and hot aisle runner system, this mold offers a reliable solution for mid‑ to high‑volume production runs. The support for TPE and PVC, bilateral glue injection, and flat wire 1.8 mm × 4.5 mm configurations allows manufacturers to produce USB A male outer films that are both mechanically robust and visually consistent. The specified mold lifespan of 300,000 times and the compact mold size further enhance its practicality in fast‑paced, cost‑sensitive manufacturing environments.

In summary, Product 1 – USB A male outer film mold is a specialized plug mold/wire mold/twisted tooth mold/material saving mold/hot runner system mold solution. With a carefully selected SKD11 material, heat‑treated surfaces, S45 mold frame, four‑cavity configuration, support for TPE/PVC bilateral glue injection, flat wire 1.8 mm × 4.5 mm compatibility, outlet hole size of 3.5 mm, and a 300,000‑shot design life, it provides a comprehensive and efficient option for producing high‑quality USB A male outer films.