Project Overview
A mobile device manufacturer required precision lens covers for smartphone cameras. The project demanded ultra-high clarity, extreme precision, and scratch resistance.
Challenge
- Optical Clarity: 95%+ light transmission
- Precision: ±0.05mm tolerances
- Scratch Resistance: Hard coating for durability
- Volume: 5M+ units annual production
- Cost: Competitive for consumer electronics
Solution
Precision Manufacturing
- Polycarbonate with optical-grade clarity
- Precision molding with tight process control
- Hard coat application for scratch resistance
- Automated inspection for defects
Quality Excellence
- CMM verification on all critical dimensions
- Light transmission testing
- Scratch resistance validation
- 100% automated visual inspection
Results
| Metric | Target | Achieved |
|---|---|---|
| Light Transmission | 92% | 95% |
| Tolerance | ±0.1mm | ±0.05mm |
| First-Pass Yield | 98% | 99.9% |
| Annual Volume | 3M units | 5M+ units |
| Field Failures | <50 PPM | 0 PPM |
Customer Testimonial
“CoreLMould’s lens covers are optically perfect. ±0.05mm precision, 95% clarity, and 99.9% yield. Essential component for our flagship phones.”
- Procurement Director, Mobile Device Manufacturer