Industry Overview
With the rise of OWS (Open Wireless Stereo) true wireless earphones, demand for ear hooks, ear clips, and neckband products is growing rapidly. From simple silicone ear tips to complex bone conduction headphones, LSR components play a critical role in earphone products—comfort, sound isolation, and waterproof performance all depend on silicone component quality.
We provide comprehensive support from early ID design through structural design, DFM analysis optimization, and full-process product development. Our final products successfully achieved mass production of 800,000+ units within the specified timeframe.
Technical Challenges
Miniature Dimensional Precision
OWS ear clip LSR overmolding thickness is mostly under 0.6mm, requiring tolerance control within 0.05mm. This demands extremely high mold precision and molding process control.
Hardness Control
Earphone silicone requires appropriate hardness (typically 40-60 durometer). Too hard causes discomfort, too soft causes deformation—requiring precise formulation and molding control.
Surface Quality
Earphone silicone covers contact skin directly. Surface must be free of any defects, oil stains, or bubbles—requiring strict process design and control.
Durability Testing
Ear hooks and ear clips must pass rigorous durability tests: 10,000+ bending cycles, sweat immersion, high-low temperature cycling, and more.
Our DFM Solutions
- Precision Mold Design: Using high-precision machining equipment, mold precision up to ±0.01mm, ensuring stable product dimensions
- Runner Optimization: Unique runner balance design ensures uniform filling, avoiding bubbles and sink marks
- Cooling System: Optimized cooling channel design reduces product deformation and improves dimensional stability
- Material Formulation: Partnering with renowned silicone manufacturers to provide formulations best suited for earphone applications
Key Process Points
Mold Precision
±0.01mm machining precision
Deformation Control
SR+LSR simultaneous design
Process Design
One-stop process service
Success Case
OWS Ear Hook Project
We provided comprehensive support from structural design to DFM analysis and optimization, fully participating in product development. The final product passed 10,000 bending tests and IPX68 waterproof certification, achieving mass production of 800,000 units.