Case Study
Industry: Precision Industrial
The precision industrial electronics company referenced in this case study has spent years developing unique devices related to complex three-dimensional measurement applications, detailed imaging, and supplemental realization solutions. The advanced technology developed by this company has become increasingly important in varying industries that depend on real-time data to make informed decisions quickly. Several industries including law enforcement, aerospace, and industrial manufacturing facilities commonly use these products to improve their performance and efficiency metrics. In this case, this precision industrial electronics company was faced with a unique challenge that called for over 50 individual molds for separate parts for a singular 3D measuring device. A vast majority of these individual components featured complex designs essential to the final product performance. Furthermore, this company approached Seaway with exceedingly tight deadlines and quality standards to lower the chance of supply chain interruption to their customers.
Our Objective
This company approached Seaway Plastics with the specific objective of developing fifty unique high-precision molds that allowed them to meet deadlines while emphasizing a “design for manufacturability” approach and replicable design. As this specific project did not require unique materials or molding techniques, the customer relied heavily on our industry knowledge and DFM approach to deliver results. Seaway got right to work with the client to complete the plans and used clear communication practices to encourage the collaborative efforts of both companies’ staff. With this project, time was of the essence with little room for error. However, with the two companies interfacing their extensive skills and expertise, this precision industrial electronics company received the support they needed to start. Considering the sheer number of individual molded components, the final performance of the 3D measuring device relied heavily on Seaway designing precision molds that resulted in high-precision final components with exceptionally low variability between each part. This helped to ensure that the final product performed as expected and delivered the accurate results these specific industries could rely on.
The Results
The precision industrial electronics company received product samples less than three weeks after Seaway’s in-house tooling experts completed the final product molds. The industry standard turnaround time for projects with similar part complexities and volumes can range between 6 and 10 weeks. Also, Seaway completed their project before their anticipated deadline. This project wrapped up only 10 weeks after the initial project commenced, and roughly 7 weeks from providing our first product samples to final production runs. For other manufacturers, even experienced injection molding companies, a project that involved 58 unique component molds made to strict specifications would average nearly 6 months.
Over 10,000 unique individual components were molded for this precision industrial electronics company during the project scope in 2020. Each component was rigorously tested and inspected to ensure ISO 9001 quality standards were upheld. From ensuring the grade of raw materials, to in-production checks, and post-molding inspection, Seaway was still able to deliver ahead of schedule without sacrificing quality.
Conclusion
To summarize, Seaway used collaborative communication, industry knowledge, and a design for manufacturability approach to develop over 50 separate unique components for a precision industrial electronics company manufacturing 3D measuring devices. After only three weeks, the customer was able to review injection molded samples of each component and make any necessary adjustments before moving to the production stage.
In less than ten weeks, Seaway completed the project with over 10,000 molded components delivered to the customer and ready for assembly into their final 3D measuring devices. The upfront design for manufacturability process implemented here ensured fewer drops in quality during the molding process, less additional work or issues during production, and more accurate components that improve final product quality. This successful case study is another example of Seaway’s proficiency in working within the precision electronics industry to develop detailed components through plastic molding. If you are searching for a similar product, please send us a message today with more information and we would be happy to discuss our offerings and provide a detailed quote.
