The client plans to develop a product for installing, protecting, and securing switches, sockets, or junction points. This project places high demands on the product's appearance, structural reliability, functional stability, and feasibility for mass production. The client has provided an initial concept and basic reference information and expects us to support the entire manufacturing process-from design optimization to mass production and final delivery.
Quotation Process
Depending on the completeness of the information provided by the client, our quotation process can be divided into four scenarios:
- Providing 3D (STP) Files
If the client provides complete STP files along with the intended material, we can quickly and accurately prepare a quotation after fully evaluating the structural and manufacturing feasibility.
- Providing 2D Drawings
If the client provides 2D drawings and the intended material, our engineers will create the corresponding 3D model free of charge and send it to the client for confirmation. Once confirmed, we provide an accurate quotation.
- Providing Only Product Samples
If the client sends product samples to us, our engineers will create a 3D model based on the sample and provide the 3D file to the client for confirmation free of charge. Based on the product structure and the client's budget, we recommend suitable material options. Once the material is confirmed, we provide an accurate quotation.
- Only Product Concept, No Drawings or Samples
For projects with only a preliminary concept, our design team communicates thoroughly with the client to complete the product design. After the 3D model is completed, it is sent to the client for confirmation free of charge. Then, based on the product structure and budget requirements, we recommend suitable materials and provide an accurate quotation once confirmed.
For this project, the client provided 2D drawings, which falls under the second scenario above.
Project Workflow
Submission of Client Information
At the end of June, the client sent us the product drawings along with the expected annual production volume, which served as the basis for project evaluation and quotation.
3D Design and Preliminary Plan Confirmation
Upon receiving the materials, our engineers completed the 3D structural design within one working day and provided the 3D file to the client for confirmation free of charge.
At the same time, considering the client's budget, we recommended P20 steel for mold manufacturing. Based on the product's actual application scenario, we proposed two material options-ABS V0 and ABS V1-and submitted a preliminary quotation for the client's review.
Material Confirmation and Payment
In mid-July, after internal discussions, the client confirmed the selection of the ABS V0 material option. Once both parties agreed on the pricing details, the client completed the payment the following week.
Delivery of Supporting Equipment
After the payment was made, the client promptly sent the product's supporting equipment to our company. This enabled us to verify assembly and compatibility during the subsequent trial molding and functional testing stages.
DFM Report Confirmation
Upon receipt of the payment, we conducted a systematic analysis of the product structure and manufacturing process. During the early stage of mold production, we provided the client with a DFM (Design for Manufacturability) report free of charge. By evaluating structural rationality, demolding methods, wall thickness, and production feasibility, we ensured that the product design met the requirements for mold manufacturing and stable mass production.
Mold Manufacturing Initiation
After the DFM plan was confirmed, we immediately arranged for our mold technicians to begin the mold manufacturing process. The mold production cycle was 25 days, and all processes were strictly carried out according to the confirmed plan to ensure both mold quality and delivery schedule were well controlled.
Material Inspection
To ensure smooth subsequent production, once the materials were procured, we immediately sent them to a professional testing center. This ensured that the materials fully met the product design requirements and injection molding standards, providing a reliable foundation for mold trial runs and mass production.
First Trial Molding and Issue Identification
While completing the above preparations, the mold was finished by the end of August, and we immediately arranged the first trial molding.
The trial samples showed obvious weld lines on the product surface, and certain areas were prone to burn marks. The appearance and quality did not meet the expected standards.
Issue Analysis and Mold Modification Plan
To address the issues identified, our production and mold engineers conducted a focused evaluation. After multiple adjustments to injection parameters and machine settings, the weld line problem remained unresolved.
Subsequently, we introduced a mold temperature controller to optimize melt flow and molding conditions, but the issue persisted. After a comprehensive analysis, it was decided to optimize the mold structure by changing from a single gate to two gates, improving melt flow balance and fundamentally resolving the weld line problem.
Sample Production and Client Confirmation
After completing the previous stages, we finished the first batch of trial samples in early September.
Our QC department conducted dimensional checks, weight verification, and visual inspections to ensure the samples met design and quality requirements.
Once the samples passed inspection, the client was immediately notified, and the samples were sent to the client for final confirmation.
Client Approval and Production Initiation
In mid to late August, the client received the trial samples and conducted a thorough evaluation. They expressed satisfaction with the product. Upon confirmation, the client officially issued the mass production order, approving the project to enter the production phase.
Mass Production Execution
Starting in September, we officially began mass production. The production cycle was approximately 15 days (slightly adjustable depending on product quantity).
During production, each product underwent strict manufacturing standards, was carefully wiped and cleaned, and individually packed in PP bags to ensure optimal quality and appearance before leaving the factory
Production Completion and In-Factory Inspection
By mid to late September, we completed the production and packaging of all products and immediately initiated internal factory inspection.
The inspection covered appearance, dimensions, weight, and packaging integrity to ensure that each product met quality standards before leaving the factory, preparing them for formal delivery to the client.
Client Inspection and Delivery Confirmation
We contacted the client to discuss the product inspection method. The client opted for a video inspection, so we recorded a complete video covering the unboxing and inspection process, demonstrating the product's appearance under both indoor and outdoor lighting conditions.
The video was uploaded to Google Drive, allowing the client to review the full and clear data. The client confirmed that the product quality met their requirements and arranged for the freight forwarder to pick up the goods.
Official Shipment in Early October
The products were officially shipped in early October.
Project Outcome
Through close collaboration, the project was successfully completed from design to mass production, enabling the customer to achieve:
- Successful product mass production
- Optimized manufacturing costs
- Stable and controllable product quality
- Long-term, reliable supply support
Why Choose Us
- One-stop OEM/ODM custom manufacturing services
- Professional DFM and engineering support
- In-house mold making and injection molding capabilities
- Strict quality control system
- Extensive experience in custom manufacturing projects
