In-Ceiling Speaker Brackets Injection Molding Factory

One stop services: from Mold Design to Mass Production Mold Quanties: 3 Sets Mold Cavity: Single Cavity Mold Material: S136 Plastic Material: Fire Retardant ABS Business relationship with this USA customer for 10 years

Client Background

Our client is the CEO of a publicly traded company, a leading provider of home decoration solutions based in the United States. With a strong focus on quality and innovation, Alpine Mold, as an injection molding factory, have been a trusted partner with this client for 10 years. Their commitment to delivering exceptional products and services aligns with our own values, fostering a long-term business relationship. Our partnership began with a groundbreaking project, designing and manufacturing a custom In-Ceiling Speaker Brackets. Because of our professional manufacturing experience, this client further entrusted us with over 10 new home décor projects in the past 1o years.

Project Overview

This project is a new product. The project encompassed the design, development, and production of circular plastic support brackets and corresponding metal parts. These brackets and metal components play a crucial role in securely installing speakers on ceilings, ensuring stability and safety. Our client provided his 3D drawing to us and asked us took on this significant project to manufacture in-ceiling speaker brackets.

To accommodate the client's production requirements of three different sizes and three color options, we designed and manufactured three sets of molds. Each mold set consisted of a single cavity specifically designed to produce the desired in-ceiling speaker brackets.Complying with strict fire safety regulations was of utmost importance, leading us to select fire retardant ABS as the primary plastic material for the ceiling speaker brackets.

How We Help to Accelerate New Product Development

1. Design for Manufacturability (DFM) Report

After received this client’s 3D Design Drawings of ceiling speaker brackets, our team conducted a thorough analysis and provided a DFM report, identifying potential design improvements to optimize the manufacturing process and ensure cost efficiency.

2. Mold Design and Manfacturing

To bring the client's vision to life, our engineer team collaborated closely with them to develop an optimal mold design. Considering factors such as functionality, ease of manufacturing, and cost efficiency, a single cavity mold was designed using high-quality S136 mold material. This choice ensured durability, precision, and longevity of the mold. With the mold design approved, our skilled technicians embarked on the mold making process, using FANUC CNC machining, Charmilles EDM machining etc, to fabricate the molds with utmost precision.

3. Mold Trail and Samples Confirmed

To ensure the functionality and quality of the molds, we conducted a mold trial after their fabrication. During this process, we used the molds to produce samples of speaker brackets. These samples were thoroughly inspected and evaluated for dimensional accuracy, structural integrity, and overall quality. Then we would send some samples of speaker brackets to our client to validate and confirm that they meet their expectations and requirements.

4. Speaker Brackets Injection Molding and Quality Assurance

Once our customer approved the the sample speaker brackets, we proceeded with mass production to fulfill the client's volume requirements. Our state-of-the-art injection molding machines and highly trained operators worked seamlessly to produce the plastic speaker brackets using fire retardant ABS. Throughout the production process, we implemented stringent quality control measures to ensure that the manufactured components adhered to the client's specifications and maintained the highest level of quality.

Conclusion

Alpine Mold is an injection molding factory providing full-service innovative solutions from mold design to mass production, enabled us to fulfill our client's requirements for in-ceiling speaker brackets. Our successful collaboration, built on a decade-long business relationship, facilitated effective communication and understanding of their needs. By leveraging our expertise in mold design and bulid, injection molding, and quality assurance, we delivered high-quality products that met the client's specifications and complied with fire safety regulations, which made us help our client accelerating product development and speed to market! If you have any request for new project, please feel free to contact us!