PortPlug Pro - Complete Manufacturing Specifications

All technical data required for immediate production

Commercial manufacturing license required

COMMERCIAL LICENSE REQUIRED: These specifications are provided for manufacturing under commercial license from OpenSource Terracore. Unauthorized production is prohibited.

Commercial Manufacturing

Commercial License Required

All manufacturing rights are reserved. Commercial production requires a negotiated license agreement.

Contact for licensing: opensourceterracore@gmail.com

1.0 Material Specifications

Primary Material: Thermoplastic Elastomer (TPE)

Grade: Versaflex CL2000 Series

Shore Hardness: 50A ±2

Melt Flow Index: 25 g/10min (230°C/2.16kg)

Processing Temperature: 200°C ±1°C

Mold Temperature: 35°C ±1°C

Pull-Tab Material: Nylon 6/6

Diameter: 0.8mm ±0.05mm

Tensile Strength: 80 MPa minimum

Melting Point: 260°C

2.0 Mold Design Specifications

2.1 USB-C Plug Mold (3 cavities)

Cavity Dimensions: 8.42mm × 2.64mm × 3.24mm

Draft Angle: 1° per side

Gate Type: Edge gate, 1.2mm × 0.8mm

Ejection: 4× φ2mm ejector pins

Cooling: 2× φ8mm cooling channels

Surface Finish: SPI-C1 (600 grit stone)

Tolerance: ±0.05mm critical dimensions

2.2 Lightning Port Mold (2 cavities)

Cavity Dimensions: 7.72mm × 1.52mm × 2.84mm

Draft Angle: 1.5° per side

Gate Type: Sub-gate, φ0.8mm

Ejection: 2× φ1.5mm ejector pins

Cooling: 1× φ6mm cooling channel

Surface Finish: SPI-B1 (600 grit paper)

Tolerance: ±0.03mm critical dimensions

2.3 USB-A Cover Mold (2 cavities)

Cavity Dimensions: 12.05mm × 4.52mm × 3.54mm

Draft Angle: 1° per side

Gate Type: Fan gate, 3mm width

Ejection: 6× φ2.5mm ejector pins

Cooling: 3× φ8mm cooling channels

Surface Finish: SPI-C1 (600 grit stone)

Tolerance: ±0.08mm critical dimensions

2.4 HDMI Cover Mold (1 cavity)

Cavity Dimensions: 11.52mm × 4.52mm × 3.84mm

Draft Angle: 1° per side

Gate Type: Edge gate, 1.5mm × 1.0mm

Ejection: 8× φ2mm ejector pins

Cooling: 4× φ8mm cooling channels

Surface Finish: SPI-C1 (600 grit stone)

Tolerance: ±0.08mm critical dimensions

3.0 Injection Molding Parameters

Injection Phase

Injection Speed: 70 mm/sec ±5 mm/sec

Injection Pressure: 700 bar ±10 bar

Hold Pressure: 500 bar ±10 bar

Hold Time: 6 seconds ±0.5 seconds

Cooling Phase

Cooling Time: 18 seconds ±1 second

Mold Temperature: 35°C ±1°C

Coolant Temperature: 12°C ±1°C

Material Preparation

Drying: 3 hours @ 80°C ±1°C

Moisture Content: < 0.02%

Screw Speed: 100 RPM ±10 RPM

4.0 Quality Control Specifications

4.1 Dimensional Inspection

4.2 Performance Testing

Commercial License Required

All manufacturing rights reserved. Contact for commercial licensing agreement.

Contact: opensourceterracore@gmail.com

ABN: 80662917463