Case Study: How Yihua Helped a Global Hardware Brand Optimize Performance and Cost
Modern hardware components—from fasteners and hinges to tool handles and electrical enclosures—require high precision, durability, and cost-efficiency.Hardware plastic molds have become the preferred solution to meet these demands, offering consistent quality at scale across a wide range of parts.This case study explores how Yihua supported a global hardware brand in developing robust, long-li
Hardware Plastic Molds Case Study: How Yihua Helped a Global Hardware Brand Optimize Performance and Cost
Introduction: Precision Plastic Molding for Hardware Applications
Modern hardware components—from fasteners and hinges to tool handles and electrical enclosures—require high precision, durability, and cost-efficiency.
Hardware plastic molds have become the preferred solution to meet these demands, offering consistent quality at scale across a wide range of parts.
This case study explores how Yihua supported a global hardware brand in developing robust, long-life plastic injection molds that streamlined their production and enhanced product performance.
Project Background: Reinventing Traditional Metal Parts with Injection Molded Plastics
Our client, a multinational company specializing in residential and commercial hardware, was looking to reduce weight and cost across several product lines without sacrificing durability. They needed:
- High-precision plastic molds for door locks, electrical enclosures, and cable management clips
- Materials capable of replacing metal in non-load-bearing parts
- Rapid production of over 800,000 parts annually
- Reliable Class 103 and Class 102 tooling to support ongoing production needs
Yihua was chosen as their mold manufacturing partner due to our expertise in high-tolerance molds and our ability to deliver end-to-end support from design to volume production.
The Challenge: Complex Geometries and Material Durability
Plastic parts in the hardware industry must withstand:
- Mechanical stress and repetitive use
- Exposure to moisture, UV, and chemicals
- Strict dimensional tolerances to match mating metal parts
The client required tight tolerances (±0.03 mm), custom textures, and overmolding in some components—all within a 6-week production timeline.
a Heavy Duty CNC Lathes supplier’s Solution: Advanced Tooling and Engineering Support
Custom Mold Design & Engineering Review
Our engineers conducted a comprehensive Design for Manufacturability (DFM) analysis to optimize part geometry for injection molding, ensuring proper flow, ejection, and minimal warpage.
- Applied Moldflow analysis to simulate material behavior
- Suggested minor design tweaks for mold longevity and cycle-time reduction
- Designed molds with interchangeable inserts for flexible production
Tooling: Class 102 and Class 103 Molds
We manufactured Class 102 molds using hardened P20 and H13 steel, equipped with:
- Hot runners for faster cycles
- Automated slides and lifters for complex undercuts
- SPI B-1 surface finish for visible hardware components
Material Selection and Testing
Yihua provided expert guidance on engineering-grade thermoplastics such as:
- Nylon (PA66+GF): For high-strength, temperature-resistant components
- ABS/PC blends: For enhanced impact resistance in enclosures
- TPU: For flexible tool grips and gaskets
We created and delivered T1 samples within 12 business days, meeting all dimensional and cosmetic criteria.
Results: Durable Parts, Lower Costs, and Scalable Production
| KPI | Target | Achieved by Yihua |
|---|---|---|
| Tooling Lead Time | 6 weeks | 5.5 weeks |
| Tolerance Compliance | ±0.05 mm | ±0.03 mm |
| Annual Output | 800,000+ pcs | 870,000 pcs |
| Material Waste Reduction | 15% reduction goal | 19% reduction achieved |
| Tool Lifespan | 500,000+ cycles | 600,000+ cycles |