Precision Injection Molding
A technology manufacturer required high-precision plastic enclosures for handheld electronic devices. The project demanded tight tolerances, strong durability, and consistent cosmetic quality across large production volumes.
Materials Used
PC/ABS
ABS
UV-resistant coatings
Challenges
Maintaining dimensional accuracy
Avoiding sink marks on visible surfaces
Ensuring repeatability in mass production
Outcome
Reduced rejection rate
Consistent finish across batches
Scalable manufacturing up to 50,000+ units
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Overmolded Assembly for Performance Equipment
A multi-material component required rigid structural integrity combined with a durable elastomer grip surface. Early prototypes experienced inconsistent bonding and cosmetic imperfections, creating performance concerns ahead of production release.
Materials Used
Polypropylene (PP)
TPE Elastomer
Impact-Modified Substrate
Challenges
Achieving reliable material adhesion
Controlling cosmetic consistency on surfaces
Preventing bonding failure under stress testing
Outcome
Validated material adhesion
Improved cosmetic consistency
Stable multi-material production
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Precision Injection Molding
A product development team needed to transition from low-volume prototype parts to full production tooling without compromising performance or delaying launch timelines.
Materials Used
ABS
Polycarbonate (PC)
Impact-Modified Resin
Challenges
Scaling prototype to production tooling
Maintaining tolerance at higher volumes
Avoiding launch delays
Outcome
Production-ready geometry refinement
Validated and documented parameters
Stable, repeatable manufacturing at scale
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