German Premium Office Chair Brand

One-piece glass-fiber reinforced nylon backrest mold project

PAIN POINTS

The backrest is a complex curved thin-wall part (1.8mm at thinnest). The original mold caused hesitation marks at fill ends and severe warpage after ejection, leading to assembly gap out-of-tolerance with the base.

MOTEK SOLUTION

• Used Moldflow analysis to optimize gate locations and runner balance, eliminating fill hesitation.
• Designed conformal cooling channels for uniform mold temperature, controlling warpage within 0.15mm.
• Used S136 mirror steel to achieve SPI A1 surface finish on the backrest.

"The precision of motek's backrest mold is astonishing. Our assembly line first-pass rate improved from 87% to 99.6%."

Southeast Asian Outdoor Furniture Giant

Stackable outdoor leisure chair mold project

PAIN POINTS

Outdoor chairs endure long-term sun and rain exposure with UV-resistant PP material. The old mold had low cooling efficiency, a 55-second cycle, and sink marks and weld lines at the leg roots.

MOTEK SOLUTION

• Combined beryllium copper inserts with high-thermal-conductivity steel, reducing cooling time from 22s to 12s.
• Optimized gates and venting to eliminate weld lines at leg roots, meeting outdoor-grade appearance requirements.
• 4-cavity hot runner design with robotic auto-ejection for 24-hour unmanned production.

"motek's mold doubled our capacity, reduced per-chair cost by 18%, with ROI in under 8 months."