A tier-2 automotive supplier needed an 8-cavity tool for a glass-filled PA66 connector housing held to a ±0.01 mm class tolerance on three critical features. Balanced eight-drop gating, a hardness-matched steel choice and two measured rounds of steel correction brought cavity-to-cavity variation from 0.048 mm to 0.007 mm, with a 98.6% first-pass yield at T2.
Medical Device Enclosure: Thin-Wall Cosmetic, 0.09 mm Flat
A diagnostic instrument maker needed a 1.2 mm thin-wall cosmetic enclosure that stayed flat enough to seal against a gasket. Gating to four balanced drops, splitting core and cavity temperature control and correcting the steel against measured shrinkage brought flatness from 0.45 mm to 0.09 mm, with warp under 0.12 mm across the 210 mm face.
Case Study: Warpage Control on Glass-Filled PA66 Brackets
Warpage in glass-filled PA66 is a fibre-orientation and cooling-balance problem, not a press-setting problem. On this bracket, re-gating to two balanced drops, adding conformal core cooling and correcting the steel for measured shrinkage cut twist from 1.2 mm to 0.35 mm over a 400 mm span.
Case Study: Cosmetic Thin-Wall Housing for a TWS Earbuds Charging Case
We molded a 1-out-of-4 hot-runner tool for a TWS earbuds charging case that had failed on visible flow marks, cavity-to-cavity gloss variation, and hinge loosening. Relocating the gate away from the hinge, adding conformal cooling there, and running a structured three-round trial matrix brought 0.9 mm PC/ABS housings to 98.6% yield with every critical dimension inside ±0.05 mm.
Case Study: Impact-Resistant Power Tool Housings for a German OEM
We built four production molds for a German power tool OEM’s 18 V cordless drill housing package — a PC/ABS clamshell body, a PA66-GF30 gearbox cover, and a 2K TPE grip overmold. A 14-issue DFM review cut 15% of expected tooling cost, and the finished parts passed a 2 m drop test at −20 °C in all eight orientations with zero cracks.
Case Study: Precision Robot Gripper Components for Industrial Automation Lines
We built production tooling for a German cobot gripper maker whose machined-aluminum fingers were heavy and whose local molder could not hold repeatability. A four-week prototype tool let them ship pilot units first, then a production tool with 38 critical dimensions verified on a CMM and CPk above 1.67. Tooling landed inside ten weeks.
Case Study: Precision Medical Device Components for Diagnostic Imaging Equipment
At RCH Plastic, we specialize in manufacturing high-precision injection molded components for the medical device industry. This case study details our collaboration with a European diagnostic equipment manufacturer to produce critical plastic parts for their next-generation CT imaging system — a project that demanded exceptional dimensional accuracy, material biocompatibility, and repeatable quality across production runs.