Home >> About Us >> Company News
Mar. 06, 2025
A well-known medical health brand launched an innovative portable pelvic trainer that quickly gained market share due to its exceptional performance and user experience. However, during mass production, the core component—the silicone protective cover—faced multiple quality and capacity challenges, leading to order delays and affecting market expansion.
The silicone covers experienced high defect rates of up to 25%, including surface issues such as black and white spots, foreign matter, and indentations after molding and spraying. Uneven spray coating further caused fluctuations in appearance quality. The demolding lines also caused user complaints, negatively impacting the product's reputation.
* The product exhibited offset cores, causing local bulging after assembly and compromising the stability of the product's functionality.
* Significant color inconsistencies were noted across batches, with a large deviation from the Pantone colors specified by the client.
The original supplier's yield rate was only 50%, and after an explosive increase in order volume, delivery delays exceeded 30 days, putting the client at risk of stockouts.
Yejia tailored a multifaceted approach to address the client's pain points, implementing upgrades across technology, processes, and quality control.
1. Mold Re-design: After inspecting the original molds, it was found that the cavity numbers were severely damaged. Yejia redesigned the mold's parting lines and venting systems, using high-precision CNC machining to solve issues like offset cores and bulging.
2. Refined Demolding Line: Added a polishing process to smooth out the demolding lines, enhancing tactile feel and reducing defects by 90%.
1. Five-Axis Spray Equipment + Smart Fixtures: The system ensured 360° uniform coating, controlling oil film thickness within ±0.05mm.
2. Fully Enclosed Molding Workshop: This isolation from dust contamination reduced black and white spot defects from 15% to under 1%.
1. Precise Color Control: Established upper and lower limits for color samples, inspecting all products and cross-checking batches to ensure color deviation (ΔE) was kept below 0.8.
2. Structural Optimization: Balanced wall thickness design reduced molding cycle time by 20%, boosting daily capacity to 8,000 units.
· Quality Leap: Overall yield rate improved from 50% to 98%, and the client's return rate dropped to zero.
· Capacity Breakthrough: Monthly delivery volume reached 200,000 units, and lead times were shortened to 15 days, helping the client seize the market window.
· Enhanced User Experience: Demolding line complaints were eliminated, and the final product's customer satisfaction rating rose to 4.74 stars (out of 5).
"Yejia's team solved the issues that had troubled us for months! From mold design to full process optimization, not only did they exceed our quality expectations, but they also doubled our production capacity. We've now fully transferred our finished product assembly business to Yejia." Following this successful collaboration, the client and Yejia signed a long-term strategic agreement to develop new products, including silicone components for postpartum products, to jointly explore new opportunities in the health tech sector.
With our precision mold technology, intelligent production systems, and comprehensive quality control capabilities, we provide high-value solutions for clients in medical health, consumer electronics, and more, helping products hit the market quickly while upgrading quality. Looking for a trusted medical silicone parts manufacturer, contact Yejia now.
