Case Studies

Background

A structural steel fabricator needed high-strength bolts for a public infrastructure project requiring strict compliance with mechanical and coating standards.

Challenge

The bolts had to meet high load-bearing requirements and pass third-party certification before installation.

Solution

We supported the customer by providing:

• High-strength structural bolts (Grade 8.8 / 10.9 / ASTM equivalents)

• Mechanical testing: tensile, hardness, proof load

• Coating verification: thickness, adhesion, corrosion resistance

• Full documentation: COA, COO, SGS verification reports

Batch traceability ensured full compliance with government project requirements.

Results

• All fasteners passed third-party inspection on the first submission

• Project deadlines were met ahead of schedule

• Customer secured follow-up orders for similar infrastructure projects

Client Profile

A leading furniture manufacturer producing large-volume home and office products for global retail chains.

Challenge

The client relied on multiple domestic suppliers for screws, inserts, connectors, and hardware kits. This resulted in inconsistent quality, stockouts during peak seasons, and higher procurement overhead.

Solution

We consolidated their frequently used fasteners into a unified sourcing program, standardized specifications across product lines, and introduced pre-packed hardware kits tailored to each furniture SKU.

Outcome

The client reduced procurement workload by 40%, achieved consistent product quality, and improved production continuity with a more reliable fastener supply chain.

Client Profile

A marine equipment manufacturer producing components for boats, docks, and offshore installations.

Challenge

Fasteners sourced locally showed premature corrosion due to high salinity environments. The client faced repeated warranty claims and maintenance costs.

Solution

We introduced a marine-grade fastener package using stainless steel 316, duplex steel, and specialized anti-corrosion coatings, based on application and exposure levels. We also worked with their engineering team to redesign several connection points to improve long-term durability.

Outcome

Product lifespan increased significantly, warranty claims dropped by 55%, and the client was able to promote enhanced corrosion resistance as a new selling point in their product lineup.

Background

A consumer electronics manufacturer required ultra-precise micro screws for final assembly. The screws must hold thin sheet-metal casings without stripping or deformation.

Challenge

Competitors struggled to control tolerance and thread accuracy, resulting in assembly-line delays.

Solution

We implemented:

• Tightened dimensional tolerance controls

• 100% optical inspection for thread and head consistency

• Improved lubrication and surface treatment to prevent stripping

• Batch-specific traceability for every order

Results

• 99.8% pass rate upon incoming inspection

• Reduced assembly-line defects

• Delivered consistent batches across multiple production cycles

• Customer selected us as a long-term preferred supplier

Background

A machinery OEM used a machined part as part of their fastening system. Manufacturing costs were high due to the complexity of the machining required.

Challenge

The customer needed a way to reduce cost without sacrificing performance or strength.

Solution

Our team reviewed the drawing and identified features that could be simplified. We proposed:

• Converting the machined component into a cold-forged part

• Reworking the geometry to eliminate unnecessary surfaces

• Optimizing material selection to reduce waste

Prototype samples were produced to confirm strength and tolerance.

Results

• 22% reduction in unit cost

• Shorter lead times due to faster forging cycle

• Strength and dimensional accuracy met all specifications

• Customer applied similar redesigns to other components

Background

An HVAC equipment manufacturer needed fasteners capable of withstanding harsh coastal environments. Their previous supplier provided zinc-plated parts that rusted within months.

Challenge

The client needed a solution that met both cost targets and long-term corrosion performance, especially for units installed near saltwater.

Solution

We recommended a switch from standard zinc plating to:

• A duplex coating (mechanical zinc + topcoat sealant)

• Optional upgrade to stainless steel 304/316 where necessary

• Salt-spray testing to confirm performance

Our QC team conducted coating thickness tests and corrosion tests before mass production.

Results

• 5× improvement in corrosion resistance

• Significant reduction in customer complaints

• Improved brand reputation for equipment reliability

• Customer expanded orders to additional fastener types

Background

An automotive components manufacturer experienced recurring failures in a bolt used in an engine-mounted bracket. The fastener had a high vibration load, and the customer was facing warranty claims due to premature loosening and breakage.

Challenge

The existing bolt met dimensional requirements but lacked sufficient fatigue strength. The failure rate was increasing as their production volume grew.

Solution

Our engineering team performed a material and heat-treatment analysis. We redesigned the bolt using:

• A higher-grade alloy steel

• Controlled heat treatment

• A modified thread engagement length

We also performed tensile and hardness testing along with coating optimization to improve corrosion resistance.

Results

• Zero failures reported after three months

• Extended product lifespan by 35%

• Reduced warranty costs for the client

• Customer adopted the new bolt design across multiple assemblies

Industry: Custom Molded Components / Precision Molded Parts

Project: F11-1150 – Mass Production Optimization

Background

A customer required the F11-1150 folding tube component to achieve higher surface quality, tighter tolerances, and improved assembly fit. Early samples showed surface imperfections and excessive gaps, preventing approval for mass production.

Challenge

The initial product did not meet customer requirements in two areas:

• Surface smoothness was insufficient due to limitations in the mold cavity finish.

• Dimensional tolerances caused assembly gaps that exceeded customer specifications.

To proceed to mass production, both the visual and functional performance of the component needed significant improvement.

Solutions Implemented

1. Mold Cavity Optimization

We performed precision polishing inside the mold cavity to dramatically increase surface smoothness. This process achieved a mirror-like finish, improving both appearance and consistency for mass production.

2. Engineering & Drawing Adjustments

Our engineering team reviewed and modified the F11-1150 technical drawing by:

• Reducing tolerances for improved dimensional accuracy

• Adjusting key angles for better alignment and fit

These changes ensured the molded part met strict assembly requirements.

3. Final Fit Improvement

After implementing the above adjustments, the gap between components was significantly reduced. The finished product finally matched the customer’s assembly expectations.

Outcome

The optimized surface quality and enhanced dimensional accuracy resulted in a fully approved F11-1150 product.

As a result:

• Customer requirements were met in full

• Assembly fit passed validation

• We successfully secured the customer’s bulk production order

Summary

This project demonstrates our technical capability in mold optimization, tolerance engineering, and rapid problem-solving. Through close collaboration and precise adjustments, we turned a challenging component into a successful mass production case — reinforcing our position as a reliable manufacturing partner for custom OEM projects.