How to make a good iPad case

2025-03-08 16:13:31

Crafting Premium iPad Cases Through PC Primary injection molding & TPU Secondary Overmolding

Here’s how our advanced dual-material process creates exceptional iPad cases:

1.  Structural Foundation: PC Primary Injection Molding

Material: High-grade polycarbonate (PC) with 30% glass fiber reinforcement

Process:

Precision molds (tolerance ±0.1mm) inject PC at 300-320°C

Forms rigid skeleton with:

Integrated mounting points for accessories

Reinforced corners (2.5mm thickness)

Precise camera/button cutouts (laser-verified alignment)

Advantages:

MIL-STD-810H drop protection (1.5m height)

Ultra-slim profile (1.8mm base thickness)

2.  Functional Enhancement: TPU Overmolding

Material: Anti-yellowing TPU (Shore 85A hardness)

Process:

Plasma activation of PC surface (60W, 0.5mBar)

Secondary molding at 190-210°C creates:

Shock-absorbing edges (3mm TPU encapsulation)

Non-slip grip patterns (0.3mm raised texture)

Seamless port covers (IP67 dust/water resistance)

Bonding Performance:

Peel strength ≥4.5N/mm (exceeds ASTM D903)

Passes 200,000 flex cycles (3x industry standard)

3.  Smart Integration

Apple Ecosystem Compatibility:

Built-in Hall sensor slots for auto wake/sleep

Magnetic array alignment (12-point positioning for iPad Pro)

User-Centric Design:

Multi-angle kickstand (55°/70° positions)

Pencil holder with wireless charging coil (Qi v1.3)

4.  Quality Assurance

Testing Protocols:

5,000-cycle hinge durability test

72hr UV exposure (anti-yellowing verification)

-40°C to 85°C thermal shock testing

Sustainability:

100% recyclable PC/TPU material blend

REACH-compliant antimicrobial treatment

Key Advantages vs. Competitors:

? 0.3mm ultra-precise Apple Pencil alignment

? 28% lighter than aluminum cases (avg. 310g for 12.9")

? 0.5mm raised screen lip + microfiber lining