Product Details of Injection Mold for Apple Phone Case

This document aims to elaborate on the full-process steps and cycle estimation of the injection mold for Apple iPhone series phone cases, from conceptual design to mass production delivery. Through standardized process management, we ensure project quality, control costs, and achieve on-time delivery.

1. Detailed Stages of the Entire Process

(1) Stage 1: Demand Analysis and Product Design

Estimated Cycle: 3-5 working days

Input Information: Specific Apple iPhone model, product concept diagram, 2D design sketch, or physical sample provided by the customer

Key Steps:

Demand Communication: Clarify the phone case structure (e.g., MagSafe compatibility), material (TPU, PC, silicone, etc.), surface treatment (glossy, matte, fabric-like texture, etc.), and expected production volume.

Product Design Review: Engineers conduct Design for Manufacturability (DFM) analysis, evaluate draft angles, wall thickness uniformity, and buckle design, and propose optimization suggestions to avoid subsequent production defects.

Final Confirmation: The customer reviews and confirms the DFM report and the final 3D product model.

Output Result: Mutually confirmed 3D product data usable for mold design

(2) Stage 2: Mold Design and Review

Estimated Cycle: 5-7 working days

Input Information: Final confirmed 3D product data from Stage 1

Key Steps:

Mold Structure Design: Use CAD software to complete the full 3D mold design, including mold base selection, cavity layout (number of parts per mold), parting surface determination, gating system (injection gate), cooling system, ejection system, and venting system.

CAE Analysis: Use mold flow analysis software (e.g., Moldflow) to simulate the filling, holding, and cooling processes of plastic in the mold, and predict and resolve potential issues such as shrinkage, gas marks, and warpage in advance.

Design Review: The internal team conducts a final review of the mold design plan to ensure it is reasonable, efficient, and reliable.

Output Result: Complete set of mold processing drawings, parts list, and procurement list

(3) Stage 3: Mold Part Processing and Assembly

Estimated Cycle: 15-25 working days

Input Information: Complete set of processing drawings from Stage 2

Key Steps:

Material Procurement: Purchase the scheduled mold base and mold core steel (e.g., P20, 718, S136, etc.).

Precision Processing: Sequentially perform processes such as milling, drilling, grinding, CNC (computer numerical control) milling finishing, EDM (electrical discharge machining) for electrodes and complex shapes, and WEDM (wire electrical discharge machining).

Heat Treatment and Surface Treatment: Conduct heat treatment (e.g., quenching, nitriding) on core parts to improve hardness and wear resistance; perform surface treatment (e.g., polishing, texturing) to meet product appearance requirements.

Mold Assembly: Precisely assemble all processed parts, including the installation of ejector pins, sliders, and cooling water pipes.

Output Result: A complete, testable injection mold

(4) Stage 4: Mold Testing and Sample Correction

Estimated Cycle: 5-10 working days

Input Information: Assembled mold

Key Steps:

Initial Mold Testing: Install the mold on the injection molding machine and perform trial injection production using the scheduled material.

Sample Inspection: Conduct comprehensive dimension measurement, appearance inspection, and functional testing (e.g., fitting with the actual Apple phone) on the test samples.

Problem Analysis and Correction: Adjust and modify the mold based on sample issues (e.g., flash, shrinkage, short shot). This step may require 2-3 rounds (T1, T2, T3) to achieve optimal performance.

Customer Confirmation: Send the final test samples to the customer for final approval (Production Part Approval Process, PPAP).

Output Result: Customer-signed confirmation samples and mold test report

(5) Stage 5: Mold Acceptance and Mass Production Delivery

Estimated Cycle: 2-3 working days

Input Information: Customer’s final approval of the samples

Key Steps:

Final Adjustment: Make final fine-tuning to the mold based on customer feedback.

Document Delivery: Organize and deliver complete mold documents, including final drawings and maintenance manuals.

Mold Shipment: Ship the mold to the designated production factory to prepare for large-scale injection production.

Output Result: Qualified injection mold for Apple phone cases, ready for stable mass production

2. Estimated Total Cycle

(1) Standard Total Cycle

Approximately 30-50 calendar days

(2) Explanation of Cycle Variables

Mold Complexity: Simple single-color molds have a shorter cycle; molds involving two-color molding, complex sliders, or ultra-fine texturing tend to approach or exceed the upper cycle limit.

Design Modifications: Any design changes in the mid-to-late stages of the process will significantly increase time costs.

Sample Confirmation Rounds: If there are few mold testing issues and confirmation is completed within 1-2 rounds, the cycle will be shortened; if issues are complex and require multiple modification rounds, the cycle will be extended.

Material and Resource Scheduling: The supply cycle of special steel or standard parts will also affect the overall cycle.

Through concurrent engineering and strict project management, we are committed to providing you with efficient injection mold manufacturing services for Apple phone cases while ensuring the highest quality.