{"id":22357,"date":"2024-07-31T08:24:10","date_gmt":"2024-07-31T00:24:10","guid":{"rendered":"https:\/\/firstmold.com\/?post_type=case-study&p=22357"},"modified":"2026-01-27T17:51:51","modified_gmt":"2026-01-27T09:51:51","slug":"vr-components-manufacturing","status":"publish","type":"case-study","link":"https:\/\/firstmold.com\/pt\/case-study\/vr-components-manufacturing\/","title":{"rendered":"Fabrico de RV atrav\u00e9s de moldagem por inje\u00e7\u00e3o"},"content":{"rendered":"
O primeiro auricular de realidade virtual de Ivan Sutherland, chamado \u201cSword of Damocles\u201d, pesava cerca de 10 libras (aproximadamente 4,5 kg). Era pesado e desconfort\u00e1vel de usar durante muito tempo. Por isso, era apoiada no teto atrav\u00e9s de um bra\u00e7o mec\u00e2nico. As novas t\u00e9cnicas de fabrico de RV duplicaram a leveza para tornar os dispositivos mais confort\u00e1veis para uma utiliza\u00e7\u00e3o prolongada.<\/p>\n\n\n\n
O peso m\u00e9dio dos auscultadores de realidade virtual mais recentes varia entre 500 e 800 gramas, sem a correia e a bateria. Por exemplo, o Meta Quest 3, que foi lan\u00e7ado em 2023, pesava aproximadamente 515 gramas. O Pico 4, que foi lan\u00e7ado no mesmo ano, pesava cerca de 586 gramas.<\/p>\n\n\n\n
O foco das empresas que fabricam componentes de RV est\u00e1 a mudar para um produto leve, ergon\u00f3mico e de alta precis\u00e3o\/alta resolu\u00e7\u00e3o. A tend\u00eancia est\u00e1 a transformar os auscultadores volumosos em dispositivos elegantes e utiliz\u00e1veis durante todo o dia.<\/p>\n\n\n\n
Pe\u00e7as de pl\u00e1stico no centro do fabrico de RV leve<\/h2>\n\n\n\n
A evolu\u00e7\u00e3o das pe\u00e7as de pl\u00e1stico no fabrico de RV tem sido uma estrat\u00e9gia importante utilizada pelos fabricantes para obterem leveza. Isto \u00e9 particularmente importante porque o pl\u00e1stico representa cerca de 50-70% dos componentes de RV. O inv\u00f3lucro externo, as correias da cabe\u00e7a e a estrutura interna s\u00e3o feitos principalmente de pl\u00e1sticos dur\u00e1veis. As estrat\u00e9gias de fabrico de componentes de RV em evolu\u00e7\u00e3o incluem: <\/p>\n\n\n\n
\n
Utiliza\u00e7\u00e3o de materiais avan\u00e7ados:<\/em><\/strong> Os fabricantes de RV est\u00e3o a substituir os pl\u00e1sticos tradicionais por alternativas de engenharia avan\u00e7ada, como a fibra de carbono, para reduzir o peso sem comprometer a integridade estrutural.<\/li>\n\n\n\n
Distribui\u00e7\u00e3o do peso:<\/em><\/strong> Muitos dos modelos de 2025 inclu\u00edam a utiliza\u00e7\u00e3o de um sistema de correias em forma de aur\u00e9ola para deslocar o centro de gravidade para mais perto da cabe\u00e7a do utilizador.<\/li>\n\n\n\n
Placas de circuitos impressos de interliga\u00e7\u00e3o de alta densidade (HDI):<\/em><\/strong> A tecnologia HDI \u00e9 utilizada para empacotar componentes mais pr\u00f3ximos, utilizando microvias e larguras de tra\u00e7o mais finas.<\/li>\n\n\n\n
T\u00e9cnicas de fabrico de precis\u00e3o:<\/em><\/strong> A utiliza\u00e7\u00e3o da moldagem por inje\u00e7\u00e3o VR de precis\u00e3o para as pe\u00e7as de pl\u00e1stico e outras tecnologias avan\u00e7adas, por exemplo, a moldagem a alta temperatura do vidro para as lentes, permite aos fabricantes satisfazer exig\u00eancias de elevada precis\u00e3o.<\/li>\n<\/ul>\n\n\n\n
A necessidade de resolver o desconforto f\u00edsico do utilizador (tens\u00f5es no pesco\u00e7o e dores de cabe\u00e7a) e o impulso para a cria\u00e7\u00e3o de auscultadores de RV verdadeiramente sem fios s\u00e3o alguns dos motores das inova\u00e7\u00f5es em curso na ind\u00fastria.<\/p>\n\n\n\n
Componentes estruturais e funcionais dos auscultadores RV<\/h2>\n\n\n\n
Um auscultador de realidade virtual \u00e9 um dispositivo complexo. A sec\u00e7\u00e3o frontal, tamb\u00e9m designada por visor, \u00e9 a \u00e1rea mais cr\u00edtica. Nela se encontram as lentes, os sensores e o \u201cc\u00e9rebro\u201d do dispositivo. O inv\u00f3lucro exterior de pl\u00e1stico r\u00edgido protege os componentes electr\u00f3nicos internos, ao mesmo tempo que proporciona estabilidade e conforto ao utilizador.<\/p>\n\n\n\n
Os auscultadores RV podem ser divididos em tr\u00eas partes, nomeadamente as partes estruturais externas, os componentes funcionais e as partes \u00f3pticas.<\/p>\n\n\n\n
Estruturas externas VR<\/th>
Componentes funcionais do RV<\/th>
Pe\u00e7as relacionadas com a \u00f3tica<\/th><\/tr>
Tampa frontal ou placa frontal<\/td>
C\u00e2maras de localiza\u00e7\u00e3o<\/td>
Lentes (lentes Fresnel e panqueca)<\/td><\/tr>
Interface facial (incluindo espuma ou junta de interface)<\/td>
C\u00e2maras de passagem RGB<\/td>
Pain\u00e9is de visualiza\u00e7\u00e3o<\/td><\/tr>
Sistema de correias para a cabe\u00e7a<\/td>
Sensor de profundidade<\/td>
Mecanismo de regula\u00e7\u00e3o da dist\u00e2ncia interpupilar<\/td><\/tr>
Gest\u00e3o de cabos<\/td>
Unidade de medi\u00e7\u00e3o da in\u00e9rcia<\/td>
Ajuste do relevo ocular<\/td><\/tr>
Aberturas para ventila\u00e7\u00e3o<\/td>
Sistema em um chip<\/td>
<\/td><\/tr>
<\/td>
Microfones e altifalantes<\/td>
<\/td><\/tr>
<\/td>
Bot\u00f5es f\u00edsicos<\/td>
<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n
Op\u00e7\u00f5es de materiais para componentes de fabrico de RV<\/h2>\n\n\n\n
Os materiais utilizados no fabrico de RV centram-se no equil\u00edbrio do peso para conforto e desempenho do utilizador. Outros factores que os fabricantes de RV consideram durante a sele\u00e7\u00e3o do material s\u00e3o a durabilidade e a gest\u00e3o t\u00e9rmica. Por exemplo, o inv\u00f3lucro ou revestimento exterior \u00e9 fabricado com uma precis\u00e3o apertada utilizando pl\u00e1stico de alto desempenho para equilibrar leveza e durabilidade. A precis\u00e3o apertada ajuda a manter a \u00f3tica alinhada.<\/p>\n\n\n\n
\n
Caixa VR:<\/em><\/strong> Pl\u00e1sticos como os policarbonatos (PC) e o acrilonitrilo butadieno estireno (ABS), ou a mistura PC+ABS, s\u00e3o utilizados para o inv\u00f3lucro porque equilibram rigidez e leveza. Para reduzir ainda mais o peso, os fabricantes de moldes de inje\u00e7\u00e3o de RV utilizam frequentemente paredes finas e desenhos com nervuras e treli\u00e7as.<\/li>\n\n\n\n
Componente \u00f3tico:<\/em><\/strong> Para as lentes, s\u00e3o utilizados materiais transparentes especiais com excelente resist\u00eancia aos riscos. Um bom exemplo de material utilizado para fabricar uma lente de RV \u00e9 o copol\u00edmero de olefina c\u00edclico (COC) com transmit\u00e2ncia de luz \u2265 92%.<\/li>\n\n\n\n
Conforto de utiliza\u00e7\u00e3o:<\/em><\/strong> O elast\u00f3mero termopl\u00e1stico (TPE), um material flex\u00edvel e macio, \u00e9 utilizado para componentes antiderrapantes, aumentando assim o conforto de utiliza\u00e7\u00e3o, especialmente para utilizadores de longas sess\u00f5es.<\/li>\n<\/ul>\n\n\n\n
Componentes de fabrico de RV<\/th>
Materiais comuns utilizados para fabricar componentes de RV<\/th>
Crit\u00e9rios de sele\u00e7\u00e3o do material<\/th><\/tr>
Quadro interno<\/td>
Magn\u00e9sio, alum\u00ednio, pol\u00edmero refor\u00e7ado com fibra de carbono<\/td>
Alta resist\u00eancia ao impacto, leveza, acabamento brilhante.<\/td><\/tr>
Almofada de rosto<\/td>
TPE, espuma de c\u00e9lulas abertas<\/td>
Conforto, respirabilidade, leveza.<\/td><\/tr>
Dissipador de calor<\/td>
Alum\u00ednio, cobre, grafite<\/td>
Elevada condutividade t\u00e9rmica.<\/td><\/tr>
Lente<\/td>
COC, polimetacrilato de metilo (PMMA)<\/td>
Clareza, resist\u00eancia aos riscos, transmit\u00e2ncia da luz, precis\u00e3o.<\/td><\/tr>
Correias<\/td>
Engrenagens de pol\u00edmero, poli\u00e9ster<\/td>
Resist\u00eancia \u00e0 tra\u00e7\u00e3o, baixo peso.<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n
Tecnologias-chave na conce\u00e7\u00e3o de moldes de inje\u00e7\u00e3o VR<\/h2>\n\n\n\n
O processo de conce\u00e7\u00e3o de um molde para a produ\u00e7\u00e3o de auscultadores RV envolve tecnologias especializadas e de alta precis\u00e3o. O objetivo das tecnologias-chave \u00e9 fornecer componentes leves com geometrias complexas e acabamentos de superf\u00edcie superiores.<\/p>\n\n\n\n
O processo de cria\u00e7\u00e3o de moldes para a moldagem por inje\u00e7\u00e3o VR come\u00e7a frequentemente com a utiliza\u00e7\u00e3o de software CAD, CAM ou CAE avan\u00e7ado, como o SolidWorks ou o ProE, em combina\u00e7\u00e3o com a an\u00e1lise Moldflow para garantir a conce\u00e7\u00e3o para fabrico (DFM). O software avan\u00e7ado \u00e9 crucial para otimizar a espessura da parede e o arrefecimento. Tr\u00eas aspectos-chave do design do molde de inje\u00e7\u00e3o VR incluem:<\/p>\n\n\n\n
\n
Controlo de precis\u00e3o:<\/em><\/strong> A maquinagem CNC de alta velocidade e alta precis\u00e3o \u00e9 utilizada para garantir a extrema precis\u00e3o dimensional dos moldes. Um dos principais desafios da moldagem por inje\u00e7\u00e3o com caixas VR \u00e9 conseguir uma superf\u00edcie de alto brilho sem defeitos. Isto pode ser ultrapassado atrav\u00e9s da otimiza\u00e7\u00e3o dos par\u00e2metros de moldagem por inje\u00e7\u00e3o, como a velocidade, a press\u00e3o e a temperatura. Os defeitos comuns, como a deforma\u00e7\u00e3o e a contra\u00e7\u00e3o em formas complexas, podem ser reduzidos atrav\u00e9s da otimiza\u00e7\u00e3o do sistema de arrefecimento.<\/li>\n\n\n\n
Otimiza\u00e7\u00e3o estrutural:<\/em><\/strong> Os inv\u00f3lucros curvos e as fivelas complexas enfrentam frequentemente v\u00e1rios desafios com os moldes convencionais de duas partes. Os desafios comuns na moldagem de caixas curvas em VR incluem a forma\u00e7\u00e3o de detalhes incompletos e dificuldades de desmoldagem. A estrutura multi-slide + insert foi concebida para resolver estes problemas. Pode ser utilizada para criar pe\u00e7as com cortes inferiores intrincados, multidireccionais e formas complexas.<\/li>\n\n\n\n
Tratamento de superf\u00edcie:<\/em><\/strong> As marcas de fluxo e as linhas de soldadura s\u00e3o defeitos cosm\u00e9ticos que podem resultar de um fluxo inconsistente do pl\u00e1stico fundido. A redu\u00e7\u00e3o da rugosidade micro-superficial da superf\u00edcie do molde ou o polimento espelhado reduz significativamente a resist\u00eancia ao atrito entre o pl\u00e1stico fundido e a cavidade do molde. As marcas iniciais de maquinagem s\u00e3o removidas utilizando pedras de \u00f3leo com granulometrias de 180 a 600. O alisamento \u00e9 feito com lixa h\u00famida de gr\u00e3o 400 a 1600. O polimento final \u00e9 efectuado com pasta de diamante (0,25\u00b5m ou 0,5\u00b5m).<\/li>\n<\/ol>\n\n\n\n
Requisitos do cliente<\/h2>\n\n\n\n
Um cliente especializado no fabrico de dispositivos vest\u00edveis de RV necessitava de uma tampa frontal personalizada para auscultadores de RV. O seu fornecedor anterior n\u00e3o conseguiu ultrapassar o desafio do empeno resultante das paredes extremamente finas da pe\u00e7a. Al\u00e9m disso, havia a quest\u00e3o da precis\u00e3o de montagem abaixo do padr\u00e3o.<\/p>\n\n\n\n
O cliente estava ansioso por encontrar um fabricante de moldes de inje\u00e7\u00e3o de RV que pudesse ultrapassar os desafios. O cliente ficou convencido da capacidade da First Mold para resolver os problemas depois de uma visita completa \u00e0s instala\u00e7\u00f5es da empresa e da an\u00e1lise de \u00e1lbuns de projectos anteriores. Os requisitos pormenorizados do cliente inclu\u00edam<\/p>\n\n\n\n
\n
Espessura da parede da pe\u00e7a 1,0 mm,<\/li>\n\n\n\n
Peso \u226425g,<\/li>\n\n\n\n
Sem marcas de fluxo na superf\u00edcie,<\/li>\n\n\n\n
Toler\u00e2ncia de montagem \u00b10,03mm,<\/li>\n\n\n\n
Taxa de rendimento da produ\u00e7\u00e3o em massa \u226598%<\/li>\n<\/ul>\n\n\n\n
Desafios<\/h2>\n\n\n\n
Conseguir um peso \u226425g exigiu mais do que uma simples troca de materiais. Primeiro, os engenheiros da Mold tiveram de repensar o projeto, em colabora\u00e7\u00e3o com o cliente. Foi necess\u00e1rio identificar \u00e1reas n\u00e3o cr\u00edticas utilizando a An\u00e1lise de Elementos Finitos (FEA). Foram adicionadas nervuras para garantir a rigidez, em vez de materiais s\u00f3lidos.<\/p>\n\n\n\n
Para reduzir ainda mais o peso dos auscultadores de realidade virtual, foi preferido um design de encaixe em vez de parafusos. No entanto, isso exigiu uma toler\u00e2ncia apertada para garantir que as pe\u00e7as se encaixam corretamente durante a montagem.<\/p>\n\n\n\n
Solu\u00e7\u00e3o<\/h2>\n\n\n\n
A First Mold adoptou a estrutura de moldagem por inje\u00e7\u00e3o assistida por g\u00e1s (GAIM) para a conce\u00e7\u00e3o do molde de inje\u00e7\u00e3o VR. Este m\u00e9todo oferecia vantagens significativas em rela\u00e7\u00e3o \u00e0 moldagem tradicional, utilizando g\u00e1s nitrog\u00e9nio pressurizado para criar sec\u00e7\u00f5es ocas. O GAIM reduziu a utiliza\u00e7\u00e3o de resina em mais de 20%. Tamb\u00e9m permitiu a otimiza\u00e7\u00e3o da distribui\u00e7\u00e3o do material e melhorou a qualidade geral da superf\u00edcie.<\/p>\n\n\n\n
A moldagem por inje\u00e7\u00e3o assistida por g\u00e1s cria sec\u00e7\u00f5es ocas com arrefecimento diferencial. Ou seja, as sec\u00e7\u00f5es ocas arrefecem mais rapidamente do que as sec\u00e7\u00f5es s\u00f3lidas. Por conseguinte, foi necess\u00e1rio introduzir canais de arrefecimento precisos. A otimiza\u00e7\u00e3o dos canais de arrefecimento foi importante para evitar um arrefecimento desigual, que pode levar a deforma\u00e7\u00f5es. Um canal de arrefecimento optimizado era tamb\u00e9m importante para maximizar a velocidade de produ\u00e7\u00e3o.<\/p>\n\n\n\n
O corte foi optimizado para \u00e1reas n\u00e3o vis\u00edveis. Esta decis\u00e3o de design foi tomada durante a fase CAD para garantir que as linhas de costura permanecessem ocultas. Manter as linhas de separa\u00e7\u00e3o ocultas permitiu \u00e0 First Mold manter a est\u00e9tica impec\u00e1vel do 100% na superf\u00edcie da caixa do auricular VR.<\/p>\n\n\n\n
Ajustamento do processo<\/h3>\n\n\n\n
O material selecionado para o fabrico de pe\u00e7as de pl\u00e1stico VR foi uma mistura de PC+ABS refor\u00e7ada com fibra de vidro. A combina\u00e7\u00e3o deste material com a moldagem por inje\u00e7\u00e3o assistida por nitrog\u00e9nio evita a decomposi\u00e7\u00e3o do material. Isto deve-se ao facto de o azoto atuar como um g\u00e1s inerte que desloca o oxig\u00e9nio dentro do cilindro e do molde.<\/p>\n\n\n\n
A desloca\u00e7\u00e3o do oxig\u00e9nio impede a degrada\u00e7\u00e3o do pol\u00edmero a altas temperaturas. Esta t\u00e9cnica tamb\u00e9m evita a descolora\u00e7\u00e3o e mant\u00e9m a resist\u00eancia mec\u00e2nica do pl\u00e1stico.<\/p>\n\n\n\n
Sistema de controlo de qualidade<\/h3>\n\n\n\n
A First Mold utilizou a monitoriza\u00e7\u00e3o em tempo real com sensores de press\u00e3o no molde. Os sensores mediam a press\u00e3o da cavidade (at\u00e9 2.000 bar) e a temperatura. Forneceram dados instant\u00e2neos sobre o enchimento do molde, a embalagem e o congelamento da porta para dete\u00e7\u00e3o imediata de defeitos. Isto ajudou a reduzir os refugos.<\/p>\n\n\n\n
Os engenheiros da First Mold realizaram uma inspe\u00e7\u00e3o minuciosa da pe\u00e7a acabada utilizando uma m\u00e1quina de medi\u00e7\u00e3o por coordenadas (CMM). O scanner mediu as geometrias exteriores para detetar empenos que a olho nu poderiam facilmente passar despercebidos. A medi\u00e7\u00e3o foi comparada com a planta do produto para verificar a consist\u00eancia.<\/p>\n\n\n\n
Resultados finais e testemunho de cliente<\/h2>\n\n\n\n
A First Mold n\u00e3o se limitou a entregar um molde. A empresa forneceu um sistema de moldagem por inje\u00e7\u00e3o de RV que ajudou o cliente a ultrapassar alguns dos desafios de fabrico anteriores com o seu anterior fornecedor. A solu\u00e7\u00e3o fornecida pela First Mold ajudou o cliente a criar componentes de RV leves. Isto garantiu que o seu produto fosse mais leve do que muitos dos produtos de marcas concorrentes no mercado, oferecendo aos entusiastas da RV conforto para uma experi\u00eancia de utiliza\u00e7\u00e3o mais longa.<\/p>","protected":false},"excerpt":{"rendered":"
A First Mold fornece tampas frontais de alta qualidade e duradouras para auscultadores VR utilizando moldagem por inje\u00e7\u00e3o ABS+PC, garantindo precis\u00e3o e uma est\u00e9tica superior.<\/p>","protected":false},"author":2,"featured_media":22359,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_acf_changed":false,"inline_featured_image":false,"footnotes":""},"case-study-category":[66],"case-study-tag":[75],"class_list":["post-22357","case-study","type-case-study","status-publish","has-post-thumbnail","hentry","case-study-category-injection-molding-cases","case-study-tag-consumer-electronic"],"acf":{"photo_gallery":{"case_study_gallery":[[{"id":22361,"title":"The C-side of the VR headset product","caption":"The C-side of the VR headset 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