Client Background
Company: A European luxury lifestyle brand targeting high-end consumers with premium tech accessories.
Challenge:
- Design Complexity: Needed a dual-material iPhone case combining soft TPU edgesand matte aluminum alloy accents for a premium tactile feel.
- Time Crunch: Required market-ready samples in 6 weeks to align with a flagship product launch.
- Quality Standards: Zero tolerance for cosmetic defects (scratches, color mismatch) common with multi-material manufacturing.
- Previous supplier failed to balance aesthetics and durability, resulting in a 15% defect rate.
YG’s Solution: Precision Engineering & Agile Collaboration
To meet the client’s demands, YG leveraged its end-to-end capabilities as a specialized Phone Case Manufacturer:
1. Rapid Design Optimization
1.1 Material Synergy: Selected a thermoplastic polyurethane (TPU) with Shore 85A hardness for shock absorption and 6061 aluminum alloy for rigidity.
1.2 Prototyping: Delivered 3 printed prototypes within 72 hours using in-house SLA printers, iterating based on client feedback.
2. Dual-Material Molding Technology
2.1 Overmolding Process:
Step 1: Precision CNC machining of aluminum frames (tolerance: ±0.05mm).
Step 2: Injection molding TPU onto frames using Sumitomo 350T machines with multi-shot capabilities.
2.2 Quality Assurance:
Conducted 24-hour thermal cycling tests (-20°C to 60°C) to check material bonding integrity.
Implemented automated surface inspection systems to detect micro-scratches.
3. Accelerated Timeline
| Phase | Standard Timeline | YG Timeline |
|---|---|---|
Design Finalization |
14 days |
7 days |
Mold Fabrication |
21 days |
10 days |
Sample Approval |
14 days |
5 days |
Total |
49 days |
22 days |
Results: Luxury Quality, Delivered at Speed
- Market Success: Launched on schedule, contributing to €2.3Min pre-orders within the first month.
- Quality Metrics: Defect rate reduced from 15% (previous supplier) to 2%.Achieved IP52 certification for dust resistance, enhancing product appeal.
- Client Growth: Secured shelf space in 12 high-end European retailers, including Harrods and Selfridges.
Client Testimonial
“YG’s team understood our vision for a luxury product that felt as good as it looked. Their ability to compress a 7-week process into 22 days without sacrificing quality was remarkable.”
– Sophie L., Product Director
Why YG Excels in Complex Projects
- Technical Expertise: 130+ molding machines (Sumitomo, Haitian) handle multi-material designs.
- Vertical Integration: In-house tooling, molding, and assembly eliminate third-party delays.
- Luxury Market Focus: Dedicated team for premium finishes (e.g., bead-blasting, anodizing).
