Full Turnkey Processes

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Industrial Design

Racer implements methodical protocols that bring together a balance of form and aesthetics, of fit and function. By leveraging our broad background across many disciplines, we are able to provide creative insights by consolidated proper-grounded research and deep knowledge of market trend & user experience.

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Mechanical Design

Racer’s mechanical engineering services can help you to transform ideas to manufacturability products by developing guidance models, and graphics for manufacturing process. Our mechanical design team uses the state-of-the-art tools and follow the industries’ best practices to ensure excellent manufacturing outcomes.

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Design for Manufacturing

 

Partnering with us equal to our resources will work as a true engineering extension of your company. With the help of our facility’s pre-engineering tools and years of experiences building products, we turn your products into reality is not a dream.

We carefully review and inspect your designs, and make efficient improvement & optimization on the DFM to meet the customer’s satisfaction. This doesn’t only provide our customers the opportunity to build the most reliable but also at the most reasonable and cost-effective product without compromising the ideas.

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Design for Assembly

We practice such tool to select the most cost effective material and process to be used in the production in the early stages of product design. We minimize part count and design parts with self locating features to minimize orientation and also advocate modular design.

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PCBA Design

Racer has the tools, knowledge and experience in designing PCBA that functioned and meet your project needs, despite of all the sophisticated technical issues, size or design defects that might be encountered by our customer. Customer need only provide their electronic device idea and Racer team will support it from conception to completion. Experience this one-stop PCB solution with our well-known and certified partners with various production capabilities.

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CNC Machining

We own several high speed 5 axis CNC machining which allow you the best quick turn of modeling & functional components, we machine from solid block plastics into actual finish parts.

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Silicon Molding

Using CNC as the master, we could cast the prototype using urethane from silicone rubber molds. After the urethane has cured, we remove any excess with a file or fine grit sand paper to achieve the desirable finish.

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Prototype tooling

What is the difference from other machine:-

 

  1. Its actually modify from a vertical cable or wire over mold machine, my engineer redesign the machine with bottom injection system, increase 2 more heating band to cater more heat for more vary material and also pressure sensor for feel back. Redesign a standard ejector system so it common for all. Include a cooling system like normal injection machine.

 

  1. The max parts weight is 350g, we can increase the shot weight by changing the barrel, but camping force remain same. Since everything is manual operated no cam or angular core system we can use up to 85% clamping force.

 

  1. It uses only the basic cavity and core insert no mold base. For the core we have a standard ejection system like MUB (Mold unit base) design.

 

  1. The cost is about  40% less than normal tooling.

 

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3D printing

With our semi industrial grade 3D Printer, we are able to create engineering parts quickly for validation

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Soft tooling

MUB tooling with 2-3 weeks leadtime for as low as $2,500.

We believe in an integrated approach to product development that is backed at every stage by exceptional engineering skill, cutting edge technology, and expert guidance. If you require short production runs for a niche market or market research, We can deliver. Our injection molding and tooling services are directed by our expert team with the knowledge and experience to help accelerate your product to market. We are 100% focused on delivering a range of solutions that are tailored to suit your project whether you need large, bumper sized tools or small, rapid tools.

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Harden tooling

Cycles: One million or more

Description: Built for extremely high production. This is the highest priced mold and is made with only the highest quality materials.

Molding surfaces (cavities and cores) must be hardened to a minimum of 48 R/C range. All other details, such as sub-inserts, slides, heel blocks, gibs, wedge blocks, lifters, etc. should also be of hardened tool steels.

Temperature control provisions to be in cavities, cores and slide cores wherever possible.

Over the life of a mold, corrosion in the cooling channels decreases cooling efficiency thus degrading part quality and increasing cycle time. It is therefore recommended that plates or inserts containing cooling channels be of a corrosive resistant material or treated to prevent corrosion.

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Insert molding

Insert Molding bind metal and plastics, or multiple components into a single unit.  It’s  reduce assembly or labor costs and delivers improved part strength and structure with enhanced design flexibility. We have numerous vertical injection molding machine to help by keeping in place during molding.

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2/3 Shots Overmolding

Multi-process molding combines thermoplastic injection with a wide range of other plastic processes in one machine and one mold, typically a rotary  platen which saved dramatically in cycle time and material cost.

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Structural Molding

Specific dosage additives into melted polymer, which allow specific design which require thick wall thickness, minimal warpage and overcoming sink marks. The advantage would be significant when part weight & cost reduction comparing with combination of multiple parts.

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In Mold Decoration

In the in-mold decorating (IMD) process, a preprinted label or film is inserted in the open plastic injection mold and held in place via vacuum ports. In-mold decorating eliminates a post-processing operation by allowing parts to be decorated during the molding cycle. Benefits to include enhanced manufacturing productivity, overall system cost reductions and greater design flexibility.

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Multi-Cavity tooling

Our construction of higher cavity tools and demand for better quality parts has put an increased emphasis on mold fill balancing. Our Balance of fill analysis is a measure of process consistency while injecting.

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Low pressure molding

Low pressure molding encapsulate electronics parts. It also eliminates the housing otherwise needed to contain the potting material. Low injection pressure are meet the needs of  fragile components, and low temperatures minimize heat exposure to sensitive electronics.

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Range of Tonnage Machines

We have over 550 injection molding machines ranging from 5 – 550 tons.

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Clean room injection molding

Equipped with HEPA filters and regulated temperature, humidity control, Our dedicated state of art Class 100,000 (ISO Class 8) clean room could compliant to cGMP & ISO 13485.

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Factory 4.0

Our Industry 4.0 at work, where integrated computing, networking and physical processes are revolutionising manufacturing for smart manufacturing.

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PCBA manufacturing

SMT – BGA , micro BGA, component size 0201.

Manual Insert Assembly

Prototype to mass production

High mix, low-volume to high-volume, low mix

Rework Stations

Conformal Coating

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Clean room assembly line

Our  ISO Class 8 Clean room allows us to plan and optimize our process for most medical clients. Work flows are strategically placed with process guide in a orderly manner.

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Supply Chain Management

The aspect of manufacturing is not only performance of machinery and equipment, but also depending on human technology and knowledge on international standards & certification.

As part of our Quality Educational System, we promote proactive approach to Quality Assurance & Control improvement through the acquisition of:

  • ISO 13485:2016 Medical Device, Quality Management System
  • ISO 9001:2008 transition to ISO 9001:2015 (March-2017)
  • ISO 14001:2004 transition to ISO 14001:2015 (March-2017)
  • US FDA Establishment Registration 9710609
  • Health Science Authority Medical Device Dealer’s License ES0001536

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6 Sigma

Six Sigma works on the principle that reducing variation gets to the root of any problem.  Lean Manufacturing uses basic improvements to make business processes more effective. We use a set of quality management methods, including statistical methods, and creates a special infrastructure for project within the organisation.

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Process validation

As a Medical Devices Manufacturers Process Validation is an essential part of our system , we do have our in house set of protocol of process validation (IQ, OQ & PQ).

Secondary Processes