Project Overview
A consumer electronics brand partnered with CoreLMould for production of premium smart watch enclosures featuring dual-material construction for enhanced user experience.
Challenge
The project required:
- Dual-Material Construction: Rigid ABS structural core with soft TPE overmold for grip
- Ultra-Thin Walls: 0.6mm nominal wall thickness with <0.1mm variation
- Premium Finish: Class A surfaces with no visible gate or flow marks
- Color Consistency: ΔE <0.5 across all production lots and batches
- High Volume: 2 million units annually with seasonal demand fluctuations
Solution
2K Molding Process
- Specialized 2K injection molding machine with rotary platen
- Sequential overmolding with optimized bond strength
- Gate design at non-visible areas with cold runner system
- Real-time process monitoring for bond quality
Tooling Design
- Hardened steel cores and cavities for longevity
- Quick-change mold inserts for color switching
- Integrated temperature control for consistent flow
- Prototype tooling for design validation before production
Color Management
- Spectrophotometric color measurement (ΔE calculation)
- Master batch qualification protocol
- Pre-production color approval workflow
- In-line color verification during production
Results
| Metric | Target | Achieved |
|---|---|---|
| Cycle Time | 18 seconds | 15 seconds |
| Color Delta E | <1.0 | <0.5 |
| Bond Strength | >3 N/mm | 4.2 N/mm |
| First-Pass Yield | 96% | 98.5% |
| Cost Reduction | Baseline | 40% |
Key Success Factors
- Process Innovation: Proprietary overmolding sequence eliminating delamination
- Quality Consistency: Statistical process control on all critical parameters
- Supply Chain Reliability: Dual-source material strategy for uninterrupted production
- Design Partnership: Close collaboration with client’s industrial design team
Customer Testimonial
“The quality of the dual-material enclosure exceeded our expectations. CoreLMould’s attention to detail and process control resulted in a product that truly stands out in the market.”
- VP of Product, Consumer Electronics Brand