Like most protecting aramid fiber cellphone circumstances, our MagEZ Case Professional 3 for iPhone 14 can also be made primarily utilizing two supplies: aramid fiber and TPU.
When our case is put alongside one other aramid fiber case from different manufacturers, folks normally discover that our case seems extra slim or streamlined, however they have no idea why.
At this time, we’ll reveal the tech behind how the MagEZ Case Professional 3 was made seamless and why it represents PITAKA’s one other milestone in expertise growth.
“Seamless” Design
Seams or joints are sometimes inevitable in product manufacturing and assembling. They’re marks that present how the product is made and designed. These days, fewer and fewer merchandise are made for DIY restore or disassembly. Thus, clients appear to care much less about these seams and joints. Is it true?
For designers, they are going to strive all the things to do away with even one small seam. And Apple designers will agree.
Apple all the time tries to reduce, if not remove, the seam in each product. They apply unibody development in lots of merchandise, just like the MacBook Air, Magic Mouse, and Apple Pencil, of which the physique and body are thought-about one unit. It is not simply in regards to the pursuit of workmanship. Apple designers know very nicely that clients care about these seams too though generally they don’t seem to be conscious of it. The smaller the seam, the sleeker or extra streamlined the product seems.
That explains why designers need “seamless” design though generally they need to compromise operate. But it surely’s not that straightforward.
Challenges
It is simpler to make a product “seamless” whether it is made of 1 single materials, corresponding to plastic or aluminum, and contains a easy kind. If it is manufactured from a couple of materials, that normally means you want a couple of mould. Combining components from completely different molds would depart parting traces.
Take cellphone circumstances for demonstration. When you discover seams or joints on a cellphone case, it is manufactured from a couple of materials. Apple has made clear circumstances like no different since 2018. All clear cellphone circumstances that manufactured from two completely different supplies have this noticeable parting line. However Apple’s clear case manufactured from TPU and PC exhibits no parting line the place the 2 supplies meet. That seemingly slight distinction units Apple other than others. Do not different cellphone case makers wish to do the identical seamless design? They most likely need, however they cannot as a result of not everybody is aware of the best way to do it.
We’re proud to announce that we did it in 2021 with our protecting aramid fiber circumstances for iPhone 13 sequence. And this 12 months, we improved the expertise and made the iPhone 14 circumstances actually seamless.
The First Seamless Aramid Fiber iPhone 14 Case
Many individuals love aramid fiber for its lightness, sturdiness, and distinctive carbon fiber-like sample. Seven years have handed since PITAKA produced the primary cellphone case utterly crafted from aramid fiber in 2015. Many have joined us to provide aramid fiber circumstances.
That mentioned, aramid fiber is stiff, which is partly why we do not use aramid fiber solely in producing the absolutely protecting iPhone 14 circumstances. To have raised lip to wrap the entrance display whereas guaranteeing the case is straightforward to take away, we’ve got to mix aramid fiber with one other materials. In our case, we select versatile TPU.
To make related aramid fiber circumstances, different manufacturers use glue or one thing much like stick the aramid fiber cloth with one other materials, which isn’t a tough guess. We put our case with a competitor’s and made this comparability. Want we are saying extra?
Aramid fiber and TPU are seamlessly built-in on our MagEZ Case Professional for iPhone 14, displaying no ugly parting traces or joints. And aramid fiber extends to the perimeters of the case means additional safety and a extra comfy really feel.
3D Injection Molding Labeling
The seamless iPhone 14 case is developed by injection molding. But it surely’s completely different from regular injection molding. We enhanced it and developed 3D Injection Molding Labeling, which we began to make use of on New Case Professional for iPhone 13 sequence.
When aramid fiber is flowing to fill the mould to kind the form we set, we inject TPU into the identical mould, by which manner two supplies mix collectively.
Two completely different supplies have completely different ratios of thermal growth and contraction, resulting in many issues on the seams throughout in-mold molding. For instance, if the quantity of two supplies is completely different on the seams, the product might need extreme flash. Due to this fact, the management of the diploma of accuracy and the thermal deformation ratio of the fabric is the important thing. With a view to seamlessly mix aramid fiber and TPU on the facet, we have to exactly management the dimensional accuracy and deformation ratio of aramid fiber, and we want particular machines with enormous tonnage initially utilized in car and different industries that give enormous strain and may do speedy heating and cooling. Solely beneath excessive strain with the expertise of switching excessive and low temperature right away can we make sure the precision of aramid fiber to provide the peerlessly seamless cellphone case crafted from two supplies.
The injection molding course of apart, we have additionally made different enchancment on the protecting iPhone 14 case. For instance, the aramid fiber we used is processed by thermoforming, which implies the fabric is reusable.
Here is a video to how we made our MagEZ Case Professional 3.
From the accuracy of 0.1mm to 0.01mm, from one line to zero line, the required effort and dedication are large. Though the method is extra sophisticated, we consider our clients need and deserve actually good issues.
Wrap-Up
Seams are associated to the manufacturing course of. Good manufacturing gear or manufacturing processes can higher management the seams. Nevertheless, the manufacturing course of is simply a method. If there is no such thing as a pursuit of higher design, there will not be innovation or evolution by way of manufacturing or industrial growth.
The MagEZ Battery Pack is one other product we tried to make seamless. As a substitute of digging holes on the facet to place the button and LEDs, we conceal them on the entrance facet of the facility financial institution to make the product extra minimalist. We’re engaged on the carbon fiber fountain pen by combining carbon fiber and metallic.
We wish to be these designers pursuing perfection to maneuver the gear of commercial innovation ahead.
