Project Overview
Our engineering partner — a global OEM sourcing plastic products and metal parts — required a single manufacturing partner capable of covering injection molding production, CNC machining, die casting, and 3D printing under one roof. This case study explains how we consolidated a fragmented supply chain into a reliable, end-to-end production program.
Client Background
The client is a mid-sized industrial equipment brand serving the automotive, consumer electronics, and home appliance markets. They previously sourced plastic products, injection molds, resin material components, and metal part customization from four different vendors, which caused inconsistent quality, lengthy lead times, and rising logistics costs.
The Challenge
- Inconsistent tolerances and surface finishes across multiple vendors
- Long, unpredictable lead times for injection mold tooling
- No unified quality documentation for die casting and CNC machining
- Difficulty scaling prototype volumes produced via 3D printing
- Limited flexibility in resin material selection for high-temperature parts
Our Solution
We delivered a fully integrated manufacturing program covering design, tooling, and mass production.
Injection Molding Production
Using high-precision injection machines ranging from 50 to 1,300 tons, we produced durable plastic products with tight tolerances. Custom steel injection molds were designed in-house, enabling rapid sampling and stable cycle times for high-volume injection molding production.
CNC Machining
For low-to-medium volume and high-accuracy components, our multi-axis CNC machining centers delivered precise metal parts with excellent repeatability — ideal for functional prototypes and end-use engineering components.
Die Casting & Metal Part Customization
Aluminum and zinc die casting provided strong, lightweight metal parts, while our metal part customization service handled secondary operations such as drilling, tapping, anodizing, and powder coating to deliver turnkey components.
Resin Material Selection & 3D Printing
We selected the optimal resin material for each application — from ABS and PC to glass-filled nylon — and used 3D printing for fast, cost-effective prototyping before committing to tooling.
Process Workflow
| Stage | Capability | Outcome |
|---|---|---|
| Design & DFM | Engineering review | Optimized part geometry |
| Tooling | Injection mold fabrication | 15-day tool lead time |
| Prototyping | 3D printing & CNC machining | 48-hour samples |
| Mass Production | Injection molding production & die casting | Stable monthly output |
| Finishing | Metal part customization | Turnkey finished goods |
Results
| Metric | Before | After |
|---|---|---|
| Number of suppliers | 4 vendors | 1 partner |
| Average lead time | 8–10 weeks | 4–5 weeks |
| Defect rate | 3.2% | 0.6% |
| Unit cost | Baseline | −18% |
| Annual production | 220,000 pcs | 640,000 pcs |
Key Takeaways
- A single integrated partner reduced supply chain complexity and total cost
- In-house injection mold tooling accelerated time-to-market
- Combining 3D printing, CNC machining, and die casting covered every volume stage
- Robust quality control improved consistency across plastic products and metal parts
