Case Studies | Plastic Injection Molding Projects | JBRplas on JBRplas

POS Terminal PIN Pad Housing: Precision Mold with Tamper-Evident Features for Payment OEM

Fri, 22 May 2026 00:00:00 +0000

Project Overview

A payment terminal manufacturer developing a PCI PTS-compliant countertop POS terminal required a production mold for the PIN entry pad enclosure — the customer-facing component that houses the keypad, display window, and EMV chip card reader slot. The enclosure is the primary user interaction surface of the terminal and directly incorporates security features that are part of the device’s tamper-evidence architecture.

The part combines three demanding requirements in a single molding: precision tolerances for the EMV card reader slot, tamper-evident snap-fit geometry for PCI PTS enclosure requirements, and ESD-safe material properties to protect sensitive payment processing electronics.

Blood Glucose Meter Housing: Medical-Grade ABS Mold with Test Strip Slot Precision

Tue, 19 May 2026 00:00:00 +0000

Project Overview

A diagnostics company developing a next-generation blood glucose monitoring system required a production mold for the meter enclosure — a two-piece handheld housing consisting of a front shell (display window, button apertures, test strip slot) and a rear shell (battery compartment, data port opening). The device is an over-the-counter Class II medical device requiring FDA 510(k) clearance, which meant the plastic enclosure and its manufacturing documentation had to support the regulatory submission.

Smart Plug Enclosure: 8-Cavity ABS V-0 Mold for Smart Home Brand

Tue, 19 May 2026 00:00:00 +0000

Project Overview

A European smart home brand developing a new Wi-Fi smart plug required a production mold for the enclosure assembly — a two-piece housing consisting of a main body and snap-fit top cover. The enclosure is a mains-connected device (230V AC) requiring UL 94 V-0 flame retardant rating, a compact internal volume to accommodate the PCB and relay, and a cosmetic exterior finish suitable for a premium consumer product sold at retail.

Construction Toy Brick System: Precision Snap-Fit ABS Molds for Licensed Toy Brand

Fri, 15 May 2026 00:00:00 +0000

Project Overview

A toy company holding a major entertainment license required a production partner for a new construction toy system — interlocking bricks, plates, and specialty connector elements compatible with an existing building toy ecosystem. The project required 4 distinct molds producing 16 unique part numbers, a total annual volume exceeding 50 million pieces, and compliance with toy safety standards across EU (EN71), US (ASTM F963 / CPSIA), and Australian (AS/NZS 8124) markets.

Smart Home Hub Enclosure: ABS FR V-0 High-Cavitation Mold for Electronics OEM

Wed, 05 Mar 2025 00:00:00 +0000

Project Overview

A consumer electronics brand developing a new smart home hub required a production mold for the device enclosure — a two-tone ABS shell with a matte textured top surface and gloss side panels. The enclosure is a mains-powered device, requiring UL 94 V-0 flame retardant rating. The client required 1.2 million enclosures per year, demanding a high-cavitation solution with cycle time under 30 seconds.

Part Specifications

Parameter	Specification
Part	Smart home hub enclosure body (single piece)
Dimensions	120 × 120 × 55mm
Wall thickness	1.8mm nominal
Material	ABS FR, UL 94 V-0 rated
Exterior finish	VDI 27 matte texture (top), SPI B1 semi-gloss (sides)
Cosmetic standard	Class A on all visible exterior surfaces
Colour	RAL 9003 Signal White
Flame retardancy	UL 94 V-0 at 1.6mm wall thickness
Annual volume	1,200,000 pieces
Target cycle time	<30 seconds

Engineering Approach

Cavity Count and Cycle Time Analysis

At 1.2 million pieces per year and a 30-second target cycle time, the production requirement calculates to:

Medical Diagnostic Device Housing: Clean Room PC Injection Molding

Mon, 10 Feb 2025 00:00:00 +0000

Project Overview

A medical device OEM developing a portable point-of-care diagnostic analyzer required a two-part plastic housing for the device enclosure. The housing needed to be produced in USP Class VI polycarbonate, molded in a clean room environment, and supported by full lot traceability documentation to support the client’s 510(k) submission and Device History Record.

The device enclosure is a Class II medical device component — non-implantable, patient-facing, requiring surface biocompatibility and resistance to hospital-grade disinfectants.

Automotive HVAC Bracket: PA66-GF30 Mold for Tier 1 Supplier

Mon, 20 Jan 2025 00:00:00 +0000

Project Overview

A European Tier 1 automotive supplier approached JBRplas requiring a precision injection mold for an HVAC bracket — a structural component mounted inside the dashboard assembly that supports the air distribution duct system. The part needed to withstand under-dashboard temperatures up to 110°C continuous, survive 30G vibration testing, and meet PPAP Level 3 documentation requirements.

Challenge: Previous supplier had failed PPAP due to unacceptable warpage on the long flat face of the part — a 180mm unsupported span that distorted by up to 1.2mm after ejection.