SOLUTIONS

Client Problem
A packaging manufacturer had sealing issues on flip-top caps. CMM checks showed drift of up to ±0.03 mm on the thread pitch diameter and sealing land of the core pins, causing poor thread engagement and leakage during validation.

Root Cause
The problem came from instability in the previous supplier’s process, including worn grinding tools, machining heat distortion, residual stress after heat treatment, and weak control of thread-related CTQ features.

What We Changed
We rebuilt the machining route around the critical thread geometry by using Hardinge CNC lathes, Böhler steel with controlled heat treatment, lower-heat machining strategy, and Zeiss CMM verification linked to assembly and leak test results.

Result
The updated core pins improved dimensional consistency, stabilized sealing contact, and reduced leakage risk in production validation.

The Problem
A medical device manufacturer faced dimensional instability in the cores of a 32-cavity syringe mold. Cavity-to-cavity variation reached ±0.015 mm, causing flash during molding and reducing consistency.

Root Cause
The issue came from the previous supplier’s roughing strategy, which created unstable cutting load in deep rib areas. This led to tool deflection and uneven stock before finishing.

What We Changed
We rebuilt the process for 58 HRC hardened cores using a Makino F5 for high-speed semi-finishing, Sandvik CBN tools for stable cutting, Sodick EDM for fine rib details, and CMM checks during and after machining.

Result
Cavity-to-cavity matching improved to ±0.005 mm, flash was eliminated in trial molding, and electrode consumption dropped by 40%.