I. Project Overview

As a global leading provider of precision molds and advanced manufacturing solutions, we are committed to addressing manufacturing challenges in the consumer electronics industry where both aesthetics and functionality are critical, through an integrated approach combining innovative design + precision machining + scientific injection molding + intelligent control. This case demonstrates how our comprehensive solution integrating two-shot molding technology + fully automated metal insert loading + scientific injection molding processes enabled a world-leading action camera manufacturer to transition from traditional overmolding to integrated two-shot molding, achieving leak-free sealing at a depth of 20 meters underwater, a 20% increase in production capacity, and a 15% improvement in product yield —setting an industry benchmark.

II. Customer Requirements & Industry Challenges

In 2025, the customer planned to develop a new generation of high-performance action cameras, requiring exceptional sealing performance, high structural strength, and efficient mass-production capability for extreme sports applications. From the early development stage, we worked closely with the customer's R&D and production teams and identified three core challenges:

Key Challenge	Description	Industry Challenge
Insufficient Sealing Performance	Traditional overmolding requires secondary processing, and micro-gaps can easily form at the interface between soft and rigid materials, making it difficult to meet long-term use requirements at a depth of 20 meters underwater	Conventional processes make it difficult to achieve seamless integration of soft and rigid materials
Excessive Manufacturing Lead Time	A split housing requires multiple molds and multiple assembly processes, resulting in a lead time of more than 70 days from mold development to mass-production delivery	Tight product launch windows cannot be met by conventional processes
Production Efficiency Bottleneck	Metal insert installation and product removal are performed in separate steps, requiring extensive manual intervention and limiting both production capacity and yield	Semi-automated production is widely used across the industry, creating a clear efficiency ceiling

III. Technical Challenge Analysis

Requirement	Technical Requirement	Industry Challenge
Micropillar Structure	IP68 protection, with zero defects at the interface between soft and rigid materials in two-shot molding	Different shrinkage rates between soft and rigid materials can easily cause flow marks, weld lines, or delamination at the bonding interface
Mold Delivery Lead Time≤35 Days	From order confirmation to completion of the T1 mold trial	Two-shot molds have complex structures, and conventional mold manufacturing typically requires more than 50 days
Production Capacity Increase≥20%	Integrated two-shot molding replaces the traditional overmolding process	Traditional processes require two sets of molds + two processing steps, resulting in low efficiency
Product Yield Increase≥15%	Full-process automation to reduce manual intervention	Metal insert installation and product removal are performed separately, resulting in a high rate of human error

IV. Intelligent Manufacturing Solution

To address the customer's three core requirements, we proposed "Innovative Mold Design + Precision Component Machining + Scientific Injection Molding Process + Intelligent Production Line Integration" as an integrated four-in-one high-end precision intelligent manufacturing solution.

1. Integrated Two-Shot Molding — A Breakthrough in Sealing Performance

Figure 1: Using high-precision two-shot injection mold technology, two injections of rigid engineering plastic (PC) and soft elastomer (TPU/TPE) are completed in a single mold in one molding cycle. Molecular-level bonding between the soft and rigid materials is achieved inside the mold, eliminating the secondary assembly gaps associated with traditional overmolding processes and ensuring leak-free long-term use at a depth of 20 meters underwater.

Figure 2: Using high-precision two-shot injection mold technology, two injections of rigid engineering plastic (PC) and soft elastomer (TPU/TPE) are completed in a single mold in one molding cycle. Molecular-level bonding between the soft and rigid materials is achieved inside the mold, eliminating the secondary assembly gaps associated with traditional overmolding processes and ensuring leak-free long-term use at a depth of 20 meters underwater.

Figure 1. Schematic Mold Design

Figure 2. Rotary Two-Shot Injection Mold

Two-Shot Injection Molding Machine Turntable

2. Rapid Delivery — T1 Mold Trial Completed in 35 Days

Leveraging our more than 30 years of technical expertise in precision molds and our well-established supply chain management system, we completed the process from order receipt to T1 mold trial in just 35 days, followed by another 35 days for mold modification and full validation, ensuring rapid market launch for the customer’s product.

Mass Production Project Schedule

3. Intelligent Production Line Integration — Improved Efficiency and Yield

We innovatively integrated high-precision fully automated metal insert loading equipment with a robotic take-out system into the two-shot injection molding production line, enabling simultaneous metal insert installation and product removal, significantly reducing the production cycle time per part. The line is equipped with a high-performance servo control system and an optimized clamping structure, ensuring unmatched repeatability and stability throughout the injection molding process while effectively controlling product shrinkage and deformation.

Fully Automated Robotic System for Metal Insert Placement and Part Removal + Real-Time Monitoring of Plastic and Metal Components

Real-Time Airtightness Monitoring and Inspection in Mass Production

V. Quantified Results & Shared Value

Original Customer Challenges	Our Solution	Final Results
Insufficient Sealing Performance	Integrated two-shot molding with molecular-level bonding between soft and rigid materials inside the mold	100% pass rate in sealing tests at a depth of 20m underwater
Excessive Manufacturing Lead Time	Rapid precision mold manufacturing + concurrent engineering management	T1 mold trial completed in just 35 days, with mass-production delivery completed in 70 days
Low Production Efficiency	Fully automated metal insert loading + synchronized robotic part removal	Production capacity increased by 20%, with manual intervention reduced by 60%
Unstable Yield	Servo control system + scientific injection molding process window optimization	Product yield increased by 15%
Persistently High Costs	Single-mold integrated molding replacing two sets of molds + multiple processing steps	Overall production costs reduced by 20%, with improved product gross margin

VI. Key Advantages

From traditional overmolding to integrated two-shot molding, and from a 70-day delivery cycle to a T1 mold trial completed in just 35 days, we leveraged the dual drivers of technological innovation + production line integration to help a world-leading action camera brand maintain its leadership in the extreme imaging equipment market. If you are also facing consumer electronics manufacturing challenges involving stringent sealing requirements, rapid delivery, and complex product structures, we welcome you to partner with Senjun Intelligent Manufacturing to jointly define the next generation of highly competitive products.