Unassembled Injection Moulded Components for Flat-Pack Product Assembly

This is the supply model where we mould the parts, you build the product. It suits buyers who want to keep the final assembly close to their market, who already run an assembly line, or who need to ship components flat to reduce freight volume. We supply every part loose, degated and cleaned, with the assembly interface documented.

What we supply

• Housing shell halves with internal ribs and screw bosses
• Front and rear panels, including window and display openings
• Snap-fit brackets, hinges, latches and living hinges
• Pins, shafts and inserts where metal is required
• Hardware: screws, threaded inserts, and spring steel clips, bagged per assembly

Why buy unassembled

Shipping an assembled product means shipping air. A flat-pack housing costs a fraction of the freight of the same housing closed, and the buyer avoids the duty and damage risk of a finished unit. Assembly is also where labour is cheapest, which is rarely the same place as the tooling, so splitting moulding from assembly is usually a cost decision as much as a logistics one.

Specification

The interface is the deliverable

Anyone can mould a part. What makes an unassembled supply work is the interface data: the drawing of every mating face, the specified interference or clearance, the torque value on every screw, and the order of assembly. We supply a 2D assembly drawing and a DFM report with the first article, and we flag every feature that can be assembled backwards, because a housing that clips in two orientations will eventually be clipped wrong on a night shift.

Tooling and lead time

Tooling is quoted per part with the steel grade and cavitation stated, typically P20 for 300k shots or S136 for 1M shots where the part is abrasive or needs a polished finish. First article is 25 to 35 days from drawing approval. Repeat orders run without the tooling lead time, and we hold tooling in our own shop rather than the buyer's, which keeps the repeat order a purchase-order decision rather than a tool transfer project.