Client Background & Product Requirements

A globally renowned audio brand planned to develop a high-end outdoor Bluetooth speaker that combines "premium aesthetics" with "extreme environmental durability." The client required the product exterior to feature a flawless, piano-black finish while achieving an IPX7 waterproof rating and superior impact resistance.

Given the highly complex internal structure—which integrates acoustic cavities, PCBAs, and waterproof seals—the client sought a partner capable of providing a "Turnkey Solution" encompassing everything from mold development and injection molding to back-end electronic assembly.

Manufacturing Challenges

• Surface Quality & Weld Line Issues: Traditional injection molding often produces visible weld lines, making it impossible to achieve the seamless mirror finish required by the client.
• Stringent Waterproofing Standards: The product had to meet IPX7 standards, requiring a perfectly airtight bond between the housing and soft-touch buttons with zero margin for error.
• Acoustic Consistency: The dimensional precision of internal cavities directly affects sound quality. Any minor deviation in molding shrinkage could lead to unwanted resonance or abnormal noise.
• Supply Chain Complexity: To mitigate procurement risks and accelerate Time-to-Market, the client aimed to consolidate plastics, electronics, and assembly with a single provider.

Foreshot’s Solutions

1. RHCM (Rapid Heat Cycle Molding) Technology

By utilizing RHCM technology, we precisely controlled mold temperatures during the injection process to eliminate weld lines and sink marks. This allowed the product to achieve a high-gloss, piano-finish aesthetic without the need for secondary painting, while also enhancing surface hardness.

2. Double-Shot / Multi-Component Injection Molding

We employed Double-Shot injection molding to integrate the rigid ABS housing with soft TPU elastomers in a single process. This not only ensured structural airtightness for waterproof buttons but also provided an excellent tactile grip, ensuring buttons remain durable and leak-proof over long-term use.

3. High-Precision Internal Structural Design

Leveraging micro-injection and precision molding techniques, we manufactured internal acoustic components to ensure consistent cavity volume, meeting strict Hi-Fi (High Fidelity) audio specifications.

4. Vertical Integration & EMS (Electronic Manufacturing Services)

Foreshot integrated mold making, injection molding, SMT, and final assembly. Within our ISO-certified cleanrooms, we performed PCBA mounting and waterproof seal testing, utilizing high-precision inspection equipment to ensure every speaker met rigorous acoustic standards before shipment.

Project Results & Value

• Exquisite Aesthetic Presentation: Successfully achieved a seamless mirror finish, passing the client's most stringent visual inspection standards.
• Superior Waterproof Performance: Testing confirmed a 99.8% yield rate for waterproofing, significantly reducing potential after-sales maintenance costs.
• Shortened Development Cycle: Through our turnkey integrated services, the lead time from design validation to mass production was reduced by 20%.
• Market Success: Upon launch, the product received high acclaim for its texture and durability, becoming the brand's best-selling outdoor audio product of the year.