How are Tablet Cases Made? | Tablet Case Manufacturing

The Process of Making Tablet Cases:  Design to Finished Product

A tablet case is a seemingly straightforward add-on, yet it requires a lot of thoughtful engineering to create a case that fits a device correctly and provides protection. The shell must correspond with the size, ports, buttons, cameras, speakers, and moving components of the tablet. Rugged designs must also be able to withstand drops, daily use, and recurring usage without getting cumbersome.

But what about the tablet cases? How are tablet cases made? The solution begins with product design and goes on to material selection, CAD development, prototype testing, mold making, injection molding, assembly, surface treatment, and quality inspection. In the case of high-volume production, all the stages must collaborate to ensure that all the finished cases fit and perform the same way.

Design of Tablet Cases Precedes Production

The engineers gather the external measurements of the tablet and research key points like the screen edge, camera, speakers, charging port, buttons, hinges, and built-in stands. The measurements are then created into a 3D CAD model. The digital model can be created with software like SolidWorks or Autodesk Fusion 360, and the geometry checked prior to starting tooling.

The design team can consider:

• Wall thickness
• Draft angles
• Corner radius
• Device clearance
• Port openings
• Button positions
• Camera clearance
• Snap-fit features
• Parting lines
• Ejection points
• Material shrinkage

These factors have a direct impact on the production of tablet cases. Even a minor error in dimensions can cause a case to be too tight, too loose, or hard to install.

How Material Selection Determines the Final Phone Case

The most typical materials are TPU, polycarbonate, silicone, ABS, and blends of rigid and flexible plastics. Polycarbonate offers a rigid structure, whereas TPU is flexible and absorbs impact.

The Surface Pro rugged case of Junchi, e.g., is based on a PC + TPU structure. The main shape is preserved by the solid polycarbonate shell, with the TPU frame offering extra protection on the edges and corners. The product is compatible with Surface Pro 4, 5, 6, 7, and 7+, and can be customized to fit, color, logo, and finish.

Processing temperature, shrinkage, cycle time, surface quality, and dimensional stability are also influenced by material selection. This is the reason why material choices ought to be made prior to the finalization of the mold.

Injection Molding Forms the Shell

One of the most popular methods of producing plastic cases in terms of tablet cases is injection molding.

• Plastic pellets are used as starting material. These are introduced into an injection molding machine where heat and mechanical movement transform the material into a molten polymer.
• The conditions of processing depend on the material and design. Engineers can regulate melt temperature, mold temperature, injection speed, injection pressure, holding pressure, and cooling time.
• As an example, the cooling process should last long enough to ensure that the part being molded is stable before ejection. When one of the parts is taken out too soon, it can deform. Overcooling, on the other hand, may cause a rise in cycle time and decrease production efficiency.

Reason Rugged Tablet Cases are Made of Various Materials

A thin tablet case can be made of a single material, whereas a rugged case can need a more complicated design. Junchi Surface Pro case has a rigid PC shell that serves as the primary protective body, with TPU as the bumper and reinforced corner sections. A precision snap-on installation structure is also used in the case.

• Depending on the design of the product, this type of construction may be made by means of separate molding and assembly or by overmolding. This is for a simple reason. There are various jobs in different regions of a case.
• The hard shell must be structurally stiff. The edge section has the advantage of flexibility. Corners might require more material since they are usually areas of impact on a drop. This renders material distribution a significant aspect of the manufacture of tablet protective cases.

The Structure is Constructed with Functional Features

Modern tablet cases are no longer just protective shells. Most of them have stands, hand straps, pen holders, shoulder straps, or other useful features. Surface Pro, a model offered by Junchi, has a pen slot, a rear hand strap, reinforced corners, and can be used with the original kickstand of the device. The case does not cover the native Surface Pro stand, but rather leaves it uncovered.

• The back shell should have sufficient clearance for the original kickstand and hinge space and yet cover the tablet. The strap should also be placed in such a way that it does not interfere with the stand.
• In the custom tablet case production, these can be modified by CAD development and ODM engineering prior to the production tooling being finalized.

Prototype to Scalable Tablet Case Production

A tablet case manufacturer is not a typical professional manufacturer, and typically, it does not go directly out of a CAD file to thousands of finished products.

The process of development typically involves CAD review, prototype development, sample inspection, tooling, mold trials, production approval, and mass production. The method provides engineers with an opportunity to detect fit or manufacturing problems prior to the production volume rising.

Junchi states that its manufacturing model assists with custom phone cases, tablet cases, laptop cases, and digital accessories, including in-house mold development and integrated production of OEM and ODM projects. BSCI and ISO 9001 certifications are also mentioned on the product page of the company.

In the case of businesses that are developing a new case, this combined method can tie up product development to tooling, material selection, customization, and production.

The Question of What Goes into a Tablet Case

The answer to how tablet cases are made is much more detailed than simply molding a piece of plastic.

• A case ready to be produced starts with proper measurements of the devices and a well-designed CAD model. This is followed by material selection, DFM review, tooling, injection molding, assembly, finishing, and quality inspection. The stages affect the end fit, strength, appearance, and usability.
• These decisions combine to create a rugged case for the Surface Pro by Junchi. Its PC + TPU design, reinforced corners, clearance for the native kickstand, pen slot, hand strap, and customizable finishes show how a tablet case can be both protective and functional.

Conclusion

A good tablet case begins way before the molding machine is turned on. Each clearance, corner, material selection, and opening is purposeful.

If you are designing a private-label, OEM, or ODM accessory, such as a tablet case, Junchi can bring your idea to life by designing the case, tooling, selecting materials, customizing, and producing in large quantities. Discover the tablet case solutions of Junchi and transform your design into a product.