Microphone Housing
Acoustic Component Manufacturing
Client
Audio Equipment Manufacturer
Year
2023
Acoustic Optimization with EMI Shielding
Our client required microphone housings that provided optimal acoustic properties while offering electromagnetic interference (EMI) shielding. The challenge was incorporating conductive additives without compromising the acoustic performance or dimensional accuracy.
The housing design required precise internal geometries to optimize sound capture while maintaining structural integrity. Traditional materials couldn't provide both acoustic and EMI shielding properties.
High-volume production of 200,000+ units monthly demanded consistent quality and minimal variation in acoustic properties.
Specialized Material Injection Molding with EMI Protection
Stone Plastics developed a specialized injection molding process using ABS with conductive additives for EMI shielding. We optimized the material blend to maintain acoustic properties while providing effective electromagnetic protection.
Our tooling design incorporates precise internal geometries optimized for acoustic performance. Advanced process controls ensure consistent distribution of conductive additives throughout each part.
The solution included: • ABS with conductive additive material development • Precision tooling for acoustic optimization • EMI shielding effectiveness testing • Acoustic performance validation • High-volume production capabilities • Statistical quality control systems
Key Outcomes
200,000+ microphone housings per month
±0.001 inch tolerance on acoustic features
99.5% EMI shielding effectiveness
Consistent acoustic performance across all units
35% cost reduction vs. metal alternatives
Stone Plastics' innovative approach to combining acoustic optimization with EMI shielding has been game-changing for our microphone products. The quality and consistency have exceeded our expectations.
Amanda Foster
Acoustic Engineering Director, PrecisionAudio Technologies
Project Gallery
Precision microphone housings with EMI shielding
Acoustic performance testing setup
High-volume manufacturing process
EMI shielding effectiveness testing
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Let's discuss how our precision injection molding capabilities can bring your product vision to life with exceptional quality and efficiency.