Customer Background：The customer is a manufacturer specializing in infusion and blood transfusion medical devices, needing to upgrade the Luer connector component in disposable infusion sets. This component directly contacts the liquid medicine, requiring strict dimensional accuracy, sealing performance and material biocompatibility, and must comply with the "Good Manufacturing Practice for Medical Devices".

Challenges Faced：① The dimensional tolerance of the internal thread of the connector needs to be controlled within ±0.01mm, and traditional molds are prone to sink marks leading to unqualified sealing; ② The molding stability of medical-grade PP material is poor, with a yield rate of only 92% during the mold testing phase; ③ The mold development cycle of the customer's original supplier is as long as 45 days, which cannot meet its new product launch plan.

Our Solutions：① At the design stage, UG 3D modeling and Moldflow analysis were adopted to optimize the gating system and cooling circuit, avoid filling defects in advance, and medical-grade mold steel was selected to ensure surface finish; ② In the processing link, FANUC machining center and SODICK wire-cutting equipment were used to realize precision processing of threaded cores with positioning accuracy up to 0.005mm; ③ In the production stage, servo injection molding machines dedicated to clean workshops were adapted, and a sterile production process covering raw materials, molding and testing was established, with all materials passing biocompatibility tests; ④ A special technical team was established to advance mold testing and customer certification document preparation in parallel.

Final Results：① The mold development cycle was shortened to 32 days, 13 days earlier than the customer's expectation; ② The product dimensional qualification rate increased from 92% to 99.5%, and the pass rate of the sealing test (no leakage under 100kPa pressure) reached 100%; ③ Won the customer's annual "High-Quality Mold Supplier" certification, with the monthly supply of supporting products exceeding 500,000 sets and the defect rate stable below 0.3%.

Customer Background：The customer is a manufacturer focusing on mid-to-high-end home and commercial fitness equipment, with core products including spin bikes, elliptical machines, etc. This time, it needed to upgrade the spin bike pedal housing — this part needs to withstand the user's weight (maximum load requirement of 200kg) and repeated stepping friction for a long time, requiring high material strength, structural stability and production efficiency.
Challenges Faced：① The traditional ABS plastic pedal housing can only bear 180kg, and is prone to cracks after long-term use, which cannot meet the needs of commercial scenarios; ② The customer's original mold adopted a single-cavity design, with a single-shift production capacity of only 800 pieces, which was difficult to match its monthly order demand of 50,000 pieces; ③ The edge of the pedal housing has complex anti-slip patterns, and traditional processing is prone to incomplete pattern filling, resulting in a yield rate of only 95%.

Our Solutions：① At the material end, glass fiber reinforced DMC composite material was selected, and the impact strength of the material was increased by 40% through formula optimization, with a load-bearing capacity of 220kg, and it also had wear-resistant and anti-aging characteristics; ② At the mold design end, UG was used to complete the 3D modeling of the double-cavity, and Moldflow analysis was used to optimize the gate position and cooling system to ensure complete filling of anti-slip patterns; ③ In the processing link, FANUC machining center was used for precision milling of the mold cavity, and a 160-ton CNC compression molding machine was used to realize efficient molding of composite materials, while establishing a special inspection process for pattern integrity; ④ At the production end, the compression parameters (temperature 165℃, pressure 120MPa) were adjusted to realize rapid mold opening and closing and improve the production cycle.

Final Results：① The product's load-bearing capacity increased from 180kg to 220kg, and the wear test (simulating 200 steps per day) life reached 50,000 times, far exceeding the customer's requirement of 30,000 times; ② The double-cavity mold increased the single-shift production capacity to 1,800 pieces, with a monthly production capacity exceeding 52,000 pieces, meeting the customer's order demand; ③ The product yield rate increased from 95% to 99.2%, and the defect rate decreased by 4.2 percentage points, helping the customer reduce production costs by about 8% and winning the customer's "Annual Core Supplier" title.

Precision equipment such as coordinate measuring machines and image measuring instruments were introduced, and a database of key mold dimensions and a product traceability system were established. The testing efficiency was increased by 40% through process optimization, the mold factory pass rate reached 100%, and the product customer complaint rate decreased by 65% year-on-year, laying a foundation for expanding the high-end auto parts market.