This process optimization targets Swaging in Lead Cartridge Heater with a tube diameter of Φ8mm-Φ12mm. The core adjustment is increasing the filling pressure from 0.8MPa to 1.2MPa, while adding a high-frequency vibration step to distribute insulating magnesium powder more evenly in the tube, with density deviation controlled within ±5%. Before optimization, some heaters had uneven heating due to non-uniform magnesium powder filling, affecting mold temperature stability; after optimization, tests on 600 samples showed that heating uniformity increased by 15%, and the mold temperature fluctuation range was reduced to ±2℃. During production, we added a magnesium powder density inspection step, randomly sampling 5 samples per batch for density testing to ensure filling quality meets standards. In addition, the optimized process shortens the filling time, improving production efficiency, with the single filling cycle reduced from 3 minutes to 2 minutes. This process optimization has been applied to the production of all Cartridge Heater for mold heating, and we will continue to track customer feedback to further optimize filling parameters and enhance the long-term stability of products.
