Cooperation with HUAWEI - A3 Steel Wrench Casting Parts (2012)

Industry: Tools & Hardware

Challenge / Problem

1. The initial design of the product was to cast it as a whole. Since the wrench handle is relatively long, it is difficult to shape it.

2. The surface of the product is copper-plated and then chrome-plated, which magnifies the surface defects of the product, resulting in a high rework rate and an increase in the scrap rate.

Solution

1. Divide the product into two sections, cast the wrench head part, and use processed steel plates for the wrench handle.

2. And connect them together by welding, which does not affect the performance of the product.

Results & Impact

The product has a better appearance and texture, and reduced the cost by about 50%, which has achieved customer satisfaction and won customer trust.

304 Stainless Steel Diffuser Impeller & Steam Valve (2016)

Industry: Mechanical Engineering

Challenge / Problem

1. The product has curved small holes connected inside, which makes it difficult to build the mold.

2. Shell making and subsequent sand cleaning during casting are difficult, resulting in a high scrap rate.

Solution

We use sand cores with good high temperature strength inside the product, which are easy to clean after high temperature, and solve the casting problem of the curved hole part very well.

Results & Impact

The product’s performance improved significantly, rework rates decreased, and delivery time was shortened. This earned customer trust and led to a long-term partnership.

316 Stainless Steel Pressure Valve Body (2018)

Industry: Equipment Manufacturing

Challenge / Problem

1. The product has a small opening and a complex inner cavity, making it almost impossible to produce.

2. It is difficult to clean the sand inside the product.

Solution

1. Open a square hole on the back of the product, use a stainless steel square plate for welding, and design a dovetail groove at the weld to improve the firmness of the weld.

2. Used high-temperature-resistant, high-strength sand cores internally, ensuring airtightness requirements were met.

Results & Impact

The product became more cost-effective, efficiency improved, and its performance in applications was enhanced, earning customer trust.

316 Stainless Steel Coffee Pot Body (2020)

Industry: Kitchen & Home Appliances

Challenge / Problem

1. The product structure is complex and the mold cannot be made as a whole.

2. The product has high verticality requirements.

Solution

1. Connected the upper and lower wax molds and used aluminum tooling blocks during the wax mold process for alignment.

2. After the product is formed, we use tooling to shape it and use a checking fixture to check the verticality.

Results & Impact

The performance and appearance of the product have been recognized by customers and a long-term cooperative relationship has been established.

AISI5140 (40Cr) High-Precision Food Film Equipment Parts (2021)

Industry: Mechanical Equipment

Challenge / Problem

1. Due to the strict tolerance requirements, most positions are suspended and the product is severely deformed.

2. The product hardness requirements are high, and customers want a hard but not brittle effect.

Solution

1. We added reinforcement ribs at the product’s openings to prevent deformation, followed by grinding treatment.

2. After wax injection, we placed aluminum blocks in severely deformed areas of the wax mold to shape it and control deformation.

3. In the post-processing stage, we used a hanging shot blasting method to reduce damage and stress impact during shot blasting.

Results & Impact

Through various process improvements, the product's performance was significantly enhanced, and the yield rate increased substantially, meeting the client's expectations.

304 Stainless Steel Motorcycle Parts (2022)

Industry: Transportation

Challenge / Problem

1. The internal shrinkage cavities of the casting are invisible from the outside, which leads to the discovery of shrinkage cavities after the inner hole is processed.

2. The deformation of the hollowed-out part in the middle of the product causes unstable dimensional tolerance.

Solution

1. We improved the feeding gate system (red area) and modified hard-to-grind areas into easily breakable sections, and also improve the shrinkage compensation effect of the product.

2. For the hollowed-out section in the middle, we used manual shaping and auxiliary inspection tools to keep dimensions within tolerance range.

Results & Impact

The stability of the product has improved, reducing rework processes, increasing efficiency, won the trust of customers, and established long-term cooperative relationships with them.

Duplex Steel Manifold (2023)

Industry: Pump & Valve

Challenge / Problem

1. Since the product is made of wax molds and the joints are deep, it is not easy to process the inner surface, and the joints inside the product are rough and uneven

2. Due to large size of products, flat surfaces are not smooth.

Solution

1. After assembling the wax molds at points A and B, we used steel sheets or round spoon tools to smooth out the internal surfaces evenly.

2. During wax injection, we placed the product’s large flat surface on a glass plate, conducting multiple inspections and adjustments before proceeding to the next process to ensure product stability.

Results & Impact

The verticality of products has improved along with better internal flatness, enhancing overall performance and internal finish quality of products. Finally, we have received recognition and positive reviews from customers.

Alloy Steel Thin-Walled Connection Clamp for Automotive Parts (2024)

Industry: Automotive

Challenge / Problem

1. The product wall thickness is very thin, which is prone to shrinkage holes.

2. The opening of the product is greatly deformed and difficult to reshape.

3. There are small teeth interfering on the periphery of the product, and the feed port cannot be placed.

Solution

1. Connect the opening of the product and place the feed port here.

2. After the product is formed, use the inspection fixture to cut off the connecting parts to meet customer requirements.

Results & Impact

Without changing the product structure, the product's practicality is enhanced, which has won the customer's praise and trust.