Project Overview
A consumer electronics company required assembly of their smart home device including housing, PCB, and connectors. The project demanded snap-fit design eliminating fasteners, ESD protection, and high-volume assembly capability.
Challenge
The primary challenges included:
- Snap-Fit Design: Reliable snap-fit assembly without screws
- Electronics Integration: Safe PCB installation without damage
- ESD Protection: Electrostatic discharge protection during assembly
- High Volume: 500K+ units annual production requirement
- Cost Reduction: Eliminate fasteners and reduce assembly time
Solution
Our engineering team developed a comprehensive solution:
Design for Assembly
- Optimized snap-fit geometry for reliable engagement
- Self-locating features for proper PCB alignment
- Strain relief for wire connections
- Serviceability features for field repair
Assembly Process
- ESD-safe assembly workstations
- Pneumatic snap-fit presses for consistent engagement
- Vision system for assembly verification
- Automated functional testing
Quality Systems
- Snap-fit engagement force testing
- Pull-test verification on all snap features
- Electrical continuity testing
- Drop testing for assembly integrity
Results
The project exceeded all targets:
| Metric | Target | Achieved |
|---|---|---|
| Annual Volume | 200K units | 500K+ units |
| Assembly Time Reduction | 40% | 60% |
| Fasteners Eliminated | 6 per unit | 6 per unit (100%) |
| Snap-Fit Failures | <0.5% | 0.01% |
| ESD Damage | 0 | 0 |
Key Success Factors
- DFM Excellence: Snap-fit design optimized for reliable assembly
- ESD Controls: Comprehensive electrostatic discharge prevention
- Automation: Efficient assembly processes enabling high volume
- Quality Validation: Rigorous testing ensuring product integrity
Customer Testimonial
“CoreLMould’s snap-fit design eliminated all screws from our product, reducing assembly time by 60% and saving significant cost. 500K+ units with zero snap-fit failures. Brilliant engineering.”
- VP of Operations, Consumer Electronics Company