PRODUCT MANUFACTURING PROCESS OVERVIEW DIAGRAM

Raw Material Selection: Setting the Tone for the Plastic Shell When environmentally friendly ABS/PC pellets arrive, the quality inspection team first conducts a "composition check" — using an infrared spectrometer to analyze material purity, ensuring no excessive impurities; sampling pellets to press into sheets, freezing them in a -20℃ low-temperature chamber for 4 hours, then testing impact resistance. Only pellets that can withstand a 1.5-meter drop without cracking are allowed into the silo. Injection Molding: Millimeter-Level "Shaping" In the injection molding workshop, mold cavities are locked after 3 rounds of high-temperature cleaning. Pellets melt in a 220℃ screw and are injected into the mold at constant pressure. As soon as the 15-second cooling cycle ends, robotic arms precisely remove the molded shells. Inspectors, wearing white gloves, run their hands over the cylinder: any 0.1mm flash or barely visible bubbles are marked for rework. The thread at the cylinder mouth undergoes a "screw fit test" — using a standard nut to screw in and out 30 times continuously, ensuring smooth operation without jamming, with tolerance strictly controlled within ±0.05mm. Precision Component Processing: Reliability Hides in Small Details Components like LED beads, battery compartments, and switches arrive simultaneously: LED beads are continuously lit in a constant temperature chamber for 72 hours, with those exceeding 5% light decay directly discarded; metal shrapnels in battery compartments are tested for contact resistance 1,000 times with a conductivity tester to ensure stable current; push-button switches undergo 5,000 press tests, with rebound force consistently maintained within the standard range of 4±0.5N. Assembly Line: Rigor Like Assembling Precision Instruments When soldering the LED bead, workers align it with the center of the cylinder head under a microscope, ensuring the beam axis deviates from the cylinder body by ≤1°; when installing the battery compartment, an "anti-reverse connection test" is conducted — intentionally reversing the battery, the flashlight must automatically power off for protection; after switch assembly, inspectors press it 30 times repeatedly, ensuring it lights up instantly without accidental activation. Semi-finished products first pass the "initial lighting check": installing test batteries to light up, using an illuminance meter to measure the brightness at the center of the 1-meter spot; any deviation exceeding ±5% is adjusted on-site by calibrating the bead angle. Finished Product Full Inspection: Simulating 100 Usage Scenarios Off-the-line flashlights must pass "three key tests": Water resistance test: IPX6 rating test, spraying with a high-pressure water gun from any direction for 3 minutes; any water ingress inside the cylinder results in failure. Impact resistance test: 1.2-meter free fall onto concrete, repeated 3 times; checking for shell cracks and functional integrity. Battery life test: installing standard batteries to light continuously, recording actual runtime; any deviation exceeding 10% from the marked value results in rework. Finally, inspectors use a strong flashlight to check the cylinder surface for scratches or color differences, even verifying the clarity of the printed LOGO with a magnifying glass. Packaging & Shipment: "Dressing" Each Flashlight in Protection Qualified flashlights are first wrapped in anti-static bags, then placed into boxes with cushioning foam — the grooves inside the box perfectly match the curvature of the flashlight, ensuring no shaking during transportation. Before shipment, warehouse managers conduct a "double check" against orders: verifying model, quantity, and batch number match the inspection report, and finally affixing the "100% inspection passed" label. From pellet to finished product, through 23 processes and 48 inspections, every plastic flashlight is equipped with the confidence to "withstand daily bumps and sudden storms" when it reaches the user’s hands.