In the manufacturing process of rotary dip switches, material selection and manufacturing process are important factors in determining product performance and cost. In this article, we will discuss in depth the materials used for rotary dip switches and the selection of manufacturing processes to help customers understand the advantages and disadvantages of different materials, as well as the impact of manufacturing processes on switch performance and cost.

1. Material selection:

a. Metallic materials: Metallic materials are commonly used to manufacture high quality rotary dip switches, such as aluminium alloy, stainless steel, and so on. Advantages include resistance to corrosion, wear and tear, high strength, etc., which can provide a good feel and long-lasting service life. However, metal materials are more expensive to manufacture and are susceptible to external electromagnetic interference, requiring insulation.

b. Engineering Plastics: Engineering plastics are another common material choice, such as polycarbonate (PC), nylon, etc.. These materials offer good abrasion resistance, impact resistance, and insulating properties at a relatively low cost. However, engineering plastics may be affected by temperature variations and chemical attack and require proper material handling and design.

c. Soft Materials: Soft materials such as silicone and rubber are commonly used for sealing components and key gaskets in rotary dip switches. These materials have good sealing and aging resistance, and can effectively prevent dust and moisture from entering the interior of the switch. However, the abrasion resistance and high temperature resistance of soft materials are poor, and need to be selected according to the actual needs.

2. Manufacturing process:

a. Injection moulding: Injection moulding is a common process used to manufacture engineering plastic parts by injecting molten plastic material into a mould, which is then cooled and cured into shape. This process has the advantages of low cost and high productivity and is suitable for mass production. However, injection moulding requires high mould manufacturing and design and is not suitable for small batch custom production.

b. Precision machining: Precision machining process includes CNC machining, laser cutting, etc., which is suitable for manufacturing high-precision and complex structure of metal parts. This process has the advantages of high processing precision and good surface quality, but the cost is higher, suitable for small batch production or special customised requirements.

c. Moulding: Moulding is a commonly used process for manufacturing soft material parts by softening thermoplastic materials by heating and pressing them into shape through moulds. This process has the advantages of high productivity and low cost and is suitable for high volume production. However, moulding has high requirements on mould design and material selection, and the fluidity and shrinkage of the material need to be fully considered.

3. Example analysis:

For example, a rotary dip switch on a high-end car audio system may use an aluminium alloy to manufacture the housing part to ensure its wear and corrosion resistance, and be manufactured by a precision machining process. The soft material sealing gasket part may be made of silicone, which is produced by moulding process to ensure its good sealing performance.

Conclusion:

In summary, the material selection and manufacturing process of rotary dip switches directly affect the performance and cost of the product. When choosing materials and processes, it is necessary to give full consideration to the design requirements, production scale and cost budget of the product to ensure that the product can meet the needs of customers and have a competitive advantage.