A leading manufacturer of electrical junction boxes faced challenges in product durability and supply chain security. By collaborating with Ningbo GP Mold Co., Ltd. (hereinafter referred to as GP Mold), they successfully optimized the injection mold design and manufacturing process, improving the durability of the electrical junction boxes and enhancing supply chain security. This project demonstrates GP Mold's expertise in the field of electrical engineering components, helping the client achieve efficient production and improved market competitiveness.
The manufacturer of electrical junction boxes for this project primarily serves industrial and construction electrical applications, such as circuit protection, wiring distribution, and outdoor installation equipment. However, in actual operation, they face multiple challenges: insufficient product durability, as the junction boxes are prone to deformation, cracking, or insulation failure in high-temperature, humid, vibrating, or chemically corrosive environments, leading to shortened product lifespan and a failure rate as high as 20%; supply chain security risks, due to reliance on multiple suppliers for mold procurement, making the supply chain vulnerable to geopolitical risks, counterfeit materials, and data breaches, resulting in significant procurement security risks and volatile costs; frequent design iterations, as traditional mold design cannot quickly adapt to new standard requirements, such as changes in size or protection levels, leading to wasted time and costs; and finally, facing market competition pressure, the manufacturer urgently needs to improve product performance to meet the needs of high-end engineering clients, but existing technology struggles to achieve precision molding and necessary safety certification standards.
The GP Mold team works closely with clients to provide a complete injection molding solution: First, professional technicians conduct on-site surveys, using 3D modeling and simulation software to optimize the design of the junction box, and incorporating hot runner and gas-assisted injection molding technologies to ensure uniform mold flow and effectively reduce stress concentration and electrical safety risks; then, high-precision molds are rapidly manufactured using CNC precision engraving milling machines and electrical discharge machining (EDM) equipment, supporting two-color molding and integrating the waterproof coating and impact-resistant structure of the junction box; in the supply chain, as a one-stop supplier, they integrate raw material procurement and mold production, establishing a secure logistics chain and supplier audit mechanism, significantly enhancing supply chain security by reducing intermediate links and effectively preventing counterfeiting risks; they also provide mold debugging services, conducting durability tests such as high-temperature aging, waterproof testing, and impact testing using injection molding machines to simulate actual production environments, and continuously iterating and optimizing based on feedback; finally, they establish a long-term cooperation mechanism, covering mold maintenance training, technical consulting, and supply chain security guidance, helping clients' internal teams comprehensively enhance their production capabilities.
Through GP Mold's systematic solutions, this project achieved remarkable results in the production and operation of electrical junction boxes. The junction boxes produced with the new molds showed a 32% increase in impact strength and a 27% improvement in corrosion resistance. The product failure rate was effectively controlled to below 5%, significantly enhancing product reliability and durability. Supply chain security was also comprehensively strengthened, with a 25% improvement in supply chain risk assessment scores. Delivery times were reduced from an average of 40 days to 28 days, effectively mitigating risks of material counterfeiting and supply disruptions, while also achieving approximately 16% in production cost savings. Production efficiency was continuously improved, with mold lifespan extended to over 550,000 cycles, significantly reducing replacement frequency. As a result, the client's annual production increased by 22%, further expanding their market share. The project's achievements were highly recognized by the client, leading to the establishment of a long-term strategic partnership and laying a solid foundation for future new product development. Overall, this project helped the client stand out in the highly competitive electrical junction box market and comprehensively promoted the achievement of their sustainable operation and development goals.
Through our efforts, the project achieved significant results
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