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- The actual service life of the mold components was increased from the industry average of 300,000 cycles to over 600,000 cycles, with flash and scratch-related complaints reduced to zero.
- The surface roughness of molded components remained stable at Ra ≤ 0.2 μm, enabling smooth demolding and improving product appearance yield from 96% to 99.6%.
- The customer listed the company as a preferred supplier for high-demand precision components, with annual procurement share increasing to over 60%.
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- The actual service life of the mold components was increased from the industry average of 300,000 cycles to over 600,000 cycles, with flash and scratch-related complaints reduced to zero.
- The surface roughness of molded components remained stable at Ra ≤ 0.2 μm, enabling smooth demolding and improving product appearance yield from 96% to 99.6%.
- The customer listed the company as a preferred supplier for high-demand precision components, with annual procurement share increasing to over 60%.
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Customer Type
Long-term purchasers of precision mold standard parts and customized components for industries such as connectors, cosmetic packaging, and medical accessories.
Pain Points
Stress Deformation
Precision inserts and punches often experience uneven stress distribution after vacuum hardening and wire cutting, leading to micro deformation and excessive deviation in subsequent fitting accuracy.
Pain Points 1
EDM Surface Defects
EDM-processed surfaces may contain micro cracks and a recast white layer, seriously affecting polishing performance and long-term fatigue life. Parts often fail due to early edge chipping or scratching.
Pain Points 2
Mold Life Requirements
Customers require molded parts with zero flash and no surface scratches, with mold life exceeding 500,000 cycles. Conventional processes are difficult to achieve stable results.
Pain Points 3
Quality Control Challenges
Batch orders require high consistency in hardness uniformity and internal quality (such as micro cracks), while traditional shipment inspection methods are insufficient.
Pain Points 4
Cryogenic Treatment & Multi-Stage Wire EDM Stress Relief Process
After rough machining, -120°C cryogenic treatment is applied to fully transform retained austenite. The finishing process adopts multi-pass slow wire cutting technology (rough cutting → precision trimming → ultra-fine finishing) to gradually release internal stress and correct heat treatment deformation. As a result, the final dimensional accuracy is stabilized within ±0.005mm.
Long-Term Surface Protection & Friction Reduction Treatment
Anti-rust emulsion is used throughout the entire machining process. PVD vacuum titanium coating (TiN/TiAlN) is additionally applied to critical forming surfaces, increasing the surface hardness to above HV 2500, significantly reducing the demolding friction coefficient and completely eliminating scratches and mold sticking.
Deep Quality Inspection System
- Each batch of sampled workpieces undergoes ultrasonic flaw detection to eliminate internal micro-cracks and shrinkage cavities.
- Coordinate Measuring Machine (CMM) is used for full inspection of geometric tolerances, while optical measuring instruments assist in rapid contour inspection.
- Each shipment is accompanied by hardness inspection records and actual surface roughness measurement reports, ensuring that every product meets the required standards.
Results / Outcomes
The actual service life of mold components increased from the industry average of 300,000 cycles to over 600,000 cycles, with flash and scratch-related complaints reduced to zero.
600,000+ Cycles
The surface roughness of molded components remained stable at Ra ≤ 0.2μm, enabling smooth demolding and improving product appearance yield from 96% to 99.6%.
Ra ≤ 0.2μm
The customer listed the company as a preferred supplier for high-demand precision components, with annual procurement share increasing to over 60%.
60%+ Procurement Share
Capabilities Demonstrated
Full Life-Cycle Process Control
Mastering the complete in-house technology chain from cryogenic treatment, multi-stage wire EDM cutting to PVD coating, without relying on outsourced processes.
Micron-Level Deformation Correction Capability
Systematically predicting and compensating for micro deformation caused by heat treatment and wire cutting, ensuring highly stable mass production.
Advanced Quality Inspection Capability
Going beyond traditional dimensional inspection by adding deeper reliability verification methods such as ultrasonic flaw detection and hardness gradient testing.
Long-Life Mold Design Collaboration
Based on customer failure modes, providing comprehensive solutions including material upgrades, coating selection, and localized structural reinforcement.
