Integrated Manufacturing
Our Integrated Manufacturing Department provides a truly one-stop, vertically integrated service, from mold development and plastic part molding to precision CNC machining, final assembly, and surface finishing. Our core mission is to solve complex process integration and procurement challenges for our clients. We eliminate the need for you to manage tolerance matching between plastic and metal components or to coordinate between assembly and finishing vendors. With expert technical skill and project management, we precisely transform your concepts into reality.
Core Technical Capabilities
- Precision Manufacturing & Molding
This foundational stage focuses on transforming raw materials into high-precision components.
Non-Metallic Molding & Hardening
Precision Plastic Injection Molding:
We specialize in thermoplastic injection molding. Leveraging our inherent advantages in mold design, we precisely control key parameters such as mold temperature, injection speed, pressure, and holding time to handle a wide range of high-performance engineering plastics (e.g., PC, ABS, PP, POM, PBT, PA) and composite materials with glass or carbon fiber additives. We also perform annealing to relieve internal stress and enhance part rigidity. Applications include high-precision mechanical components, optical-grade transparent parts, and thin-walled structures.
Metallic Forming & Precision Machining
CNC Multi-Axis Wire Forming:
Fully integrated into our quality management system, this process is dedicated to producing precision springs (compression, torsion, extension), spring clips, fasteners, and custom wire forms with strict tolerances, ensuring perfect integration with our in-house components.
Precision Stamping:
We have integrated a powerful precision stamping capacity, with presses ranging from 35 to 630 tons. Our capabilities span from single-stage blanking to complex progressive die stamping and deep drawing processes. All stamping processes and tool management adhere to Pao Tai’s strict standards and quality assurance protocols, specializing in EMI shielding cases, heat sinks, precision terminals, and structural brackets designed for zero-tolerance integration with plastic parts.
Precision Secondary Machining:
Our technical core consists of in-house multi-axis CNC milling centers, lathes, precision grinding machines, and EDM equipment. This is complemented by a network of strictly certified partner factories, creating a comprehensive machining ecosystem with both technical depth and production breadth. This model enables us to handle diverse needs from rapid prototyping and complex process development to large-scale mass production, providing maximum support and flexibility for your project.
CNC Machining: Equipped with multi-axis CNC mills and lathes for high-precision machining of both metals and engineering plastics, ideal for complex geometries or secondary operations (e.g., drilling, tapping) after molding.
Grinding: Utilizes surface, cylindrical, and internal grinding techniques for workpieces requiring superior surface roughness (Ra) and micron-level (µm) dimensional tolerances.
Electrical Discharge Machining (EDM): An extension of our core mold-making technology, including Wire EDM and Sinker EDM, used to create complex internal cavities, narrow slots, and machine high-hardness materials that are impossible with traditional cutting methods.
- Final Assembly & Integration
This stage focuses on efficiently and accurately combining individual components into functional sub-assemblies or finished products.
Ultrasonic Welding:
This technique uses high-frequency mechanical vibrations to generate frictional heat, instantly melting and fusing plastic joint surfaces under pressure. It creates high-strength, airtight, or watertight bonds without consumables, widely used for sealed enclosures, medical devices, and automotive components.
Final Assembly:
Our engineering expertise lies in the final assembly of all manufactured outputs (plastic parts, metal components, springs, stamped parts), ensuring that the function and fit of every component meet design specifications.
- Diversified Surface Finishing
This stage focuses on giving your product a brilliant, durable finish and a unique brand identity.
Coating & Plating
We integrate industry-leading surface treatment solutions. Our material engineering team matches the most suitable process and partner to your product requirements and implements Pao Tai’s quality management system to ensure a flawless final appearance.
Surface Hardening (Hard Coating):
For transparent parts like PC and PMMA or high-gloss components, we offer a UV-curable hard coating spray process. This applies a highly durable, transparent protective layer (achieving H to 3H pencil hardness) that effectively resists scratches, abrasions, and chemical corrosion. It is widely used for lenses, instrument panels, and touch panels.
Physical Vapor Deposition (PVD): Achieved through advanced equipment at our designated partners, including DAH YOUNG (H1800) Hybrid Coating Machines and CVT (H2000) Evaporation Coating Machines.
Electroplating:
A traditional electrochemical process that applies a functional or decorative metallic layer (e.g., chrome, nickel, copper) to a workpiece, providing excellent corrosion resistance and a premium metallic finish.
Precision Spray Painting:
Includes PU paint for protection and color, scratch-resistant UV-curable paint, and conductive paint for internal shielding.
Machine: Hybrid Coating Machine
Specification: H 1800, 6/8 axis
Brand: DAH YOUNG
Quantity: 1
Machine: Evaporation Coating Machine
Specification: H 2000, 6/8 axis
Brand: CVT
Quantity: 1
Post-Molding Finishing
PTmold manages all post-processing tasks by collaborating deeply with factories that are technical leaders in specific fields like curved surface pad printing, precision hot stamping, and laser engraving on special materials. Our team leads every step, from initial graphic design, color standardization (Pantone Matching), and custom fixture development to ink selection, adhesion testing, and final laser appearance during mass production.
Screen/Pad Printing:
Ink is transferred to the workpiece via a mesh screen or a silicone pad. Screen printing is ideal for flat or regular surfaces with a thick ink layer, while pad printing excels at conforming to irregular, concave, or convex surfaces, making it our most versatile printing technique.
Hot Stamping:
Heat and pressure are used to transfer metallic or colored foils onto a workpiece, creating graphics with a brilliant, mirror-like metallic finish—a key process for elevating a product's visual appeal.
Laser Engraving/Marking:
A high-energy laser beam creates permanent, high-resolution marks. This is ideal for fine details such as serial numbers, QR traceability codes, precision scales, and brand logos.
Our Core Advantages: Why Choose Us?
【Single Point of Contact, Simplified Management】 - The Advantage of Vertical Integration
The primary benefits of merging mold making and injection molding include optimizing production flow, reducing overall costs, shortening lead times, and enhancing product quality. This integration allows us to perfectly coordinate mold design with the molding process, ensuring a smooth transition from design to production and boosting overall efficiency. You interface with a single point of contact. From plastic injection, metal insert molding, ultrasonic assembly, painting, plating, hard coating, screen printing, to laser engraving, all processes are coordinated internally. This saves you significant supplier management costs and communication time.
【Proactive Risk Mitigation】 - Technical Insight from Our Mold-Making DNA
Our technical foundation is rooted in mold development, giving us a deep understanding of the interplay between materials and processes. We can anticipate and solve potential issues in the early stages of a project, reducing your development risks and costs.
【Impeccable, End-to-End Quality Control】 - Consistent Quality Across All Processes
All processes are executed under our unified quality standards. You no longer have to worry about color discrepancies between Vendor A's painting and Vendor B's printing. End-to-end quality consistency is our most solemn promise to our clients.
【Seamless Integration, Accelerated Time-to-Market】 - Shortening Your Product Development Cycle
Our one-stop service eliminates delays from transportation and waiting between multiple vendors. By creating a seamless process flow, we significantly shorten your product’s development-to-launch cycle, helping you seize market opportunities faster.
Example of an Integrated Process Flow
The production of a remote control: [Plastic Casing Injection Molding] -> [Internal Metal Spring Clip Stamping] -> [Top & Bottom Case Ultrasonic Welding] -> [Surface Painting] -> [Button Function Screen Printing] -> [Brand Logo Laser Engraving] -> [Final Product Shipment]
The Clear Choice
Choosing the Pao Tai Mold Integrated Manufacturing Department means selecting a manufacturing partner that truly understands your product and is dedicated to creating its maximum value.