Can you provide a full casing solution from prototype to mass production?

Yes. Neway provides an end-to-end casing solution that covers every stage—from early concept validation and rapid prototyping to tooling development and full-scale production. This is especially valuable for tool housings, locking systems, and outdoor device enclosures that require durability, ergonomic handling, waterproofing, and precision alignment. Our workflow integrates simulation, prototyping, molding, assembly interface design, and functional testing to ensure the final casing meets both performance and cost targets.

Step 1 – Feasibility Analysis & Design Support

Initial CAD models are reviewed for manufacturability, sealing requirements, and mechanical load distribution. Load zones, screw interfaces, and impact areas are evaluated using simulation. Design-for-manufacturing suggestions guide wall thickness, draft angles, rib layout, overmolding strategy, and zone-based material selection. This ensures the casing is production-ready before tooling investment.

Step 2 – Functional Prototyping & Testing

Prototypes are produced via CNC machining prototyping, 3D printing prototyping, or rapid molding prototyping. These allow verification of sealing features, handle ergonomics, assembly tolerances, drop behavior, and vibration resistance. Changes can be made quickly without heavy tooling costs, ensuring performance validation before mass production planning.

Step 3 – Material Selection & Process Definition

Material choice depends on zones: structural cores may use die-cast aluminum or reinforced nylon (PA), while outer shells may use ABS or PBT for cost efficiency. Sealing can be integrated using overmolding or insert molding. At this stage, fit with power tools or locking system assembly is optimized.

Step 4 – Tooling & Pilot Production

Production molds are developed with accurate tolerance control. For casings requiring IP or drop protection, parting lines, sealing grooves, and fastening features are refined. A pilot batch is produced to validate tolerance, sealing pressure, surface quality, and assembly fit. Necessary adjustments are made before scaling up production volume.

Step 5 – Mass Production & Quality Control

Full production uses controlled injection molding, overmolding, or die casting. Statistical process control (SPC) ensures dimensional stability across every batch. Surface finishes, such as painting, lacquer coating, or powder coating, can be added for enhanced appearance and durability. Each production lot is 100% validated for sealing and fit before shipment.

Step 6 – Logistics & Assembly Integration

For OEM customers, Neway provides kitting, labeling, and assembly-ready packaging support. We can supply fully assembled sub-housings or work with your existing supply chain to integrate power modules, fasteners, connectors, and EMI shielding components. This ensures seamless transition from prototyping to final product launch.