Manufacturing Challenges

In this project, the customer faced the following key manufacturing challenges:

• The grip area required a balance between structural strength and anti-slip tactile performance.
• The exterior housing needed to meet strict brand requirements for premium surface quality and visual consistency.
• Buttons and internal structural components demanded high dimensional accuracy to ensure stable and consistent operational feedback.
• During mass production, assembly tolerances and quality variation risks had to be minimized.

FORESHOT’s Solution

To address these requirements, FORESHOT provided an integrated injection molding solution. DFM (Design for Manufacturing) and process feasibility evaluations were introduced at the early mold design stage to ensure a smooth transition from product development to mass production.

Multi-Component Injection Molding

By applying multi-component (two-shot) injection molding technology, rigid engineering plastics were used as the structural core, while soft-touch materials were integrally molded in the grip area. This one-step molding process delivers both structural support and enhanced grip comfort, while significantly reducing secondary assembly operations and minimizing tolerance risks associated with post-assembly.

Micro-Structure & Premium Surface Finishing

For the controller housing and brand-identification areas, FORESHOT utilized precision mold polishing and optimized molding parameters to precisely control surface gloss and texture. This ensured compatibility with subsequent laser engraving and surface finishing processes, while maintaining consistent brand aesthetics across production batches.

Dimensional Accuracy & Stability Control

In critical structural areas—such as joystick openings, button seats, and internal brackets—FORESHOT applied high-precision mold machining and real-time process monitoring. Dimensional tolerances were consistently controlled within ±0.05 mm, ensuring stable button assembly accuracy and consistent tactile response throughout mass production.

Project Results & Customer Value

Beyond injection molding capabilities, FORESHOT supports customers early in the product development phase to reduce both design and mass production risks, establishing long-term and trusted manufacturing partnerships.

Through integrated processes and advanced manufacturing technologies, this project successfully achieved stable mass production and delivered the following tangible benefits:

• Premium appearance and tactile performance aligned with international brand quality standards.
• One-piece integrated molding design reduced assembly complexity and manufacturing risk.
• Critical structural components maintained stable tolerances within ±0.05 mm, supporting responsive button performance and long-term consistency.
• Stable mass production quality, meeting customer expectations for supply reliability.

Key Applied Technologies

• Multi-component / multi-shot injection molding
• Precision mold design and manufacturing
• Premium surface finishing and micro-structure control
• Dimensional accuracy and mass production stability control