Custom headphone parts moulding

In addition, our company has established cooperative relationships with plastic raw material suppliers, printing manufacturers, etc. to ensure the supply of raw materials and printing quality. Through our rich experience and perfect supply chain, our company can provide customers with high-quality customized custom headphone parts moulding products to meet their specific needs. At the same time, we have 10 years of professional foreign trade service experience, understand the foreign trade process, and better serve our customers. For custom headphone parts moulding products, we can make corresponding plastic parts, which is mainly done through injection molds.

The injection molding process of custom headphone parts (such as headphone shells, earbuds, and internal acoustic structural components) is a model of high precision, high appearance requirements, and multi-material application. It combines the essence of consumer electronics, ergonomics and acoustic technology.

The following is a detailed professional process for the injection molding of custom headphone parts.

The entire process of injection molding for custom headphone parts

The components of headphones typically include the headphone cavity (shell), ear tips/ear caps, internal brackets, buttons, etc. The process is complex and has extremely high requirements.

Phase One: Design and Material Selection - The foundation of appearance level, feel and sound quality

This is the first step in determining the ultimate user experience of the headphones.

Structural Design and Acoustic design

Ergonomics: The shape of the cavity must fit the auricle to ensure wearing comfort and stability.

Internal structure: Precisely designed acoustic conduits, tuning holes, and speaker unit installation positions, all of which directly affect the sound quality.

Uniform wall thickness: Prevents shrinkage, ensuring structural strength and appearance.

Material selection - Diverse functions

Headphone cavity (shell)

ABS: The most commonly used, it has low cost, good strength, is easy to spray and electroplate, and can achieve various colors and effects.

PC: It is stronger and more impact-resistant, and is often used in sports or high-end headphones.

PC/ABS alloy: It has excellent comprehensive performance, balancing strength, heat resistance and processability.

Earplugs/ear caps

TPE/TPU (Thermoplastic Elastomer) : Absolute mainstream. It offers an extremely soft and comfortable touch, fits the skin well, has good sealing performance, and enhances the passive noise reduction effect. It can be combined with a hard sound guide tube by secondary injection molding (rubber coating).

Silicone: Softer, anti-allergic, but more expensive, mostly used in high-end products. Liquid silicone rubber (LSR) injection molding is usually used instead of traditional injection molding.

Internal structural components

POM (polyoxymethylene) : Used for precision gears and slide rails (such as volume knobs), it is wear-resistant and self-lubricating.

LCP (liquid Crystal Polymer) : It is used for ultra-thin and high-precision acoustic grids (dust-proof nets), with excellent fluidity and dimensional stability.

Phase Two: Precision Mold Design and Manufacturing - A Contest at the Micrometer Level

Headphone molds are representatives of high-precision molds.

Ultra-high precision processing

Precision slow wire cutting, mirror electrical discharge machining and five-axis CNC are used to process tiny acoustic holes, complex clips and curved surfaces.

The mold steel must be made of high-grade polished steel (such as S136, NAK80).

Ultimate surface treatment

Mirror polishing: Used for shell cavities that require a high-gloss surface.

Fine etching (bite) : It is used to create matte, frosted, leather and other textures, which can not only enhance the hand feel, but also hide fingerprints and minor scratches.

Hot runner system

The needle valve type hot runner is a standard configuration, ensuring an aesthetically pleasing gate, no residue, and efficient production.

Precision exhaust system

Exhaust grooves with a depth of less than 0.015mm must be opened at the end of the melt and deep rib positions to prevent trapped gas from causing charring or incomplete filling, which is crucial for microstructures.

Special two-color/rubber-coated molds

It is used for manufacturing components that combine hard and soft rubber, such as earplugs or shells with TPE soft rubber. Precise mold rotation or sliding mechanisms are required.

Phase Three: Injection Molding Process - The combination of Art and Science

The goal of process calibration is to achieve perfect appearance, precise dimensions and low internal stress.

Strict material handling

ABS, PC and other materials must be strictly dried (for example, ABS should be dried at 80-85℃ for 3-4 hours) to prevent silver streaks.

High mold temperature process

Adopt a relatively high mold temperature (ABS/PC can be raised to 60-80℃) to achieve a high-gloss surface, reduce the strength of the weld line, and lower internal stress.

Multi-stage fine injection

Adopt a "slow-fast-slow" injection speed control to eliminate jet marks and ensure the perfect replication of mold surface details.

Clean production environment

It is recommended to produce in a 10,000-level or 100,000-level dust-free workshop to prevent dust from settling on the product surface and causing appearance defects.

Phase Four: Post-processing, assembly and ultimate quality inspection

Post-processing and secondary processing

Gate removal: Automatically completed by a mechanical hand or precisely trimmed by hand.

Spraying/electroplating: The shell needs to be sprayed with UV primer, color paint, UV topcoat, or electroplated to achieve a metallic texture.

Laser engraving/silk-screen printing: Engrave the Logo, model number or indicator light transmission hole on the shell.

Assembly

In the dust-free workshop, speaker units, PCB boards, microphones, batteries, etc. are installed into injection-molded shells.

** rigorous quality inspection ** :

100% Inspection: Under standard light sources, each part is inspected with the naked eye or automated visual inspection (AOI). No scratches, dirt spots, shrinkage or color differences are allowed.

Dimensional inspection: Use a 2D image measuring instrument or a 3D image measuring instrument to inspect the key mating dimensions.

Functional test

Acoustic testing: Frequency response curves, distortion, sensitivity, etc. are tested in an anechoic chamber to ensure that the sound quality meets the standards.

Sealing performance test: Test the sealing performance of the cavity connection.

Life test: Conduct thousands of plug and pull and press tests on buttons and interfaces.

We are a custom headphone parts moulding manufacturer, providing high-quality custom headphone parts moulding manufacturing. As long as you want to customize/develop custom headphone parts moulding products, you can find us. We have professional injection mold design and mature manufacturing technology, providing you with one-stop service, from product design-mold making-product production-product packaging-product transportation, we can help you in every link. As long as you come to us, we will provide you with the ultimate service and satisfy you in terms of product quality, production time, information dialogue, etc.

Plastic Injection Mould making

Plastic molding specifications

Mold design:

Transaction process:

Mold testing:

Product packaging

Factory

We are Custom Plastic Mold factory. Our factory is plastic injection mold maker. we has 17 years of experience in professional custom plastic mold and 10 years of foreign trade experience. We are custom Plastic Mold supplier. We can provide custom Plastic Mold service. Our factory can make the Injection molded plastic parts, and the quality of the products will satisfy you.

We have more than 50 high-end machines and hundreds of engineers and designers. We can provide one-stop service, from product design - mold making - product production - product packaging - transportation. We have a complete production chain. We can meet all your requirements.

Services we provide:

Professional custom mold service, Plastic mold design and manufacturing .plastic product production, product design, mold design, blow mold customization, rotational mold customization, die-casting mold customization. 3D printing services, CNC manufacturing services, product packaging, customized packaging, shipping services.

We always adhere to the principles of quality first and time first. While providing customers with the highest quality products, try to maximize the production efficiency and shorten production time. We are proud to tell every customer that our company has not lost any customer since its establishment.If there is a problem with the product, we will seek a solution actively and take responsibility to the end.

FAQ

Q1: Are you trading company or manufacturer ?

A: We are manufacturers.

Q2. When can I get the quotation?

A: We usually quote within 2 days after we get your inquiry.

If you are very urgent, please call us or tell us in your email so that we can quote for you first.

Q3. How long is the lead-time for mold?

A: It all depends on the products' size and complexity. Normally, the lead time is 25 days.

Q4. I have no 3D drawing, how should I start the new project?

A: You can supply us a molding sample, we will help you finish the 3D drawing design.

Q5. Before shipment, how to make sure the products quality?

A: If you don't come to our factory and also don't have the third party for inspection, we will be as your inspection worker.

We will supply you a video for production process detail include process report, products size structure and surface detail, packing detail and so on.

Q6. What is your payment terms?

A: Mold Payment: 40% deposit by T/T in advance, 30% second mold payment before sending out the first trial samples, 30% mold balance after you agree the final samples.

B:Production Payment: 50% deposit in advance, 50% before sending out the final goods.

Q7: How do you make our business long-term and good relationship?

A:1. We keep good quality and competitive price to ensure our customers benefit for best quality products.

2. We respect every customer as our friend and we sincerely do business and make friends with them, no matter where they come from.