An Australian procurement manager approached Solluna after experiencing repeated manufacturing challenges with previous suppliers. The automotive keychain project required both reliable assembly performance and premium surface finishing.
Previous suppliers provided different solutions, including injection molding and zinc die casting. However, the injection molded housing had poor assembly accuracy, while the zinc die-cast version experienced plating defects and inconsistent surface quality.
After receiving the samples, Solluna’s engineering team conducted a detailed technical analysis covering product structure, manufacturing processes, tolerances, and finishing requirements. Within 24 hours, our engineers discussed improvement options with the customer.
The proposed solution included redesigning critical assembly areas, optimizing mold structures, improving die casting parameters, and upgrading polishing and electroplating processes.
Through design optimization and supply chain integration, Solluna achieved both quality improvement and cost reduction. The injection molding solution reduced the unit cost by USD 0.35 at 15,000 pieces, while the zinc die casting solution reduced the unit cost by USD 0.51 at the same quantity.
After two weeks, improved samples were delivered and approved. Solluna also visited the customer in Australia to present technical improvements and strengthen cooperation.
The project entered successful mass production and developed into a long-term partnership. This case shows that engineering support and manufacturing optimization are critical factors in solving complex production challenges.