Case Studies

Completely new eco bottle cap design from concept sketch. No existing mold or reference product. Tight timeline to beat competitors to market.

Full CAD design → prototype validation → mold tooling → first production run completed in just 35 days from initial brief.

3 additional mold projects commissioned. Client expanded product line with KANGHAO as exclusive mold partner.

Existing mold had reached end-of-life after 500,000 cycles. Client needed exact duplication with improved steel grade for longer lifespan. Original mold documentation incomplete — reverse engineering required.

3D scanning and reverse engineering of worn mold components. Upgraded to hardened S136 steel for extended tool life. New conformal cooling channels reduced cycle time by 18%. Full dimensional verification against original part specs.

New mold rated for 1,000,000+ cycles. 18% faster cycle time improved production efficiency. Client commissioned 2 additional mold duplication projects.

Produce 4 different kitchen utensil components in a single mold cycle. Parts included spatula head, handle, measuring spoon, and clip — all with different geometries. Budget constraints required single family mold instead of 4 separate tools.

Designed balanced 4+4+4+4 family mold with optimized runner system. Flow analysis simulation ensured uniform filling across all cavity types. Interchangeable inserts for future design variations without full mold replacement.

Tooling cost reduced by 55% vs. 4 separate molds. Complete utensil set produced in one cycle. Client saved significantly on per-unit cost and launched product line 6 weeks ahead of schedule.