Custom Dishwasher Basket OEM | Home Appliance Case Study

Are you a home appliance brand struggling to find a reliable manufacturing partner who can transform your product concept into reality? This case study shows how Rayleap Plastic Inc. helped a home appliance manufacturer overcome these exact challenges through precision injection molding services.

Initial Situation

A home appliance manufacturer approached us with an ambitious goal: launch a new dishwasher basket for the North American and European markets. Their constraints were:

Material: PP with heat resistance up to 80°C and chemical resistance
Production volume: 10,000 units for market launch
Timeline: 60 days total including mold manufacturing
Pricing: Cost-effective pricing for competitive market entry

Their biggest concern? Finding a manufacturer who could handle the complete process from sample analysis to final delivery with guaranteed quality standards.

Rayleap’s Solution: Complete Manufacturing Process

Sample Analysis and Design Optimization

When the client sent us their physical sample without technical drawings, we began reverse engineering.

Our Process:

3D scanning and CAD modeling to capture exact dimensions
DFM (Design for Manufacturing) analysis identified 12 optimization opportunities

Key Improvements:

Grid structure optimization: Reduced material usage by 15% while improving strength
Draft angles: Added 2° draft to reduce cycle time by 8 seconds per par
Rib reinforcement: Strategic placement improved structural integrity by 40%
Corner improvements: Smoothed internal corners to reduce stress concentration

Result: 37% total cost reduction through design optimization while improving durability.

3D CAD drawing of custom plastic dishwasher basket design

Precision Mold Manufacturing

Mold Specifications:

Steel grade: 718H pre-hardened steel
Cavity: Single cavity design
Tolerance: ±0.05mm for critical dimensions
Expected tool life: 300,000 shots
Cold runner system with optimized gate location

Manufacturing Process:

CNC machining for cavity and core
EDM for complex geometries
Precision grinding for mating surfaces
Mirror polishing for visible areas

Quality Validation:

First article inspection using CMM
Mold flow analysis validation
Sample production and client approval

Timeline: Mold completed in 45 days, meeting the aggressive deadline.

Production with Quality Control

Equipment: 350-ton injection molding machine with automatic temperature control.
Cycle time: 50 seconds per part
Total production time: 7 days for 10,000 units

Achievement: 99.5% qualification rate, significantly exceeding ISO 9001 standards.

Final Product Results

Custom plastic dishwasher basket manufactured by injection molding

Injection mold for plastic dishwasher basket production

Injection molding process of plastic dishwasher basket in factory

Frequently Asked Questions

Q: Can you manufacture from just a product sample without technical drawings?

A: Yes. We use 3D scanning and reverse engineering to create precise CAD models from physical samples, then optimize the design for manufacturing. This is ideal for brands without in-house engineering capabilities or companies updating existing products without original CAD files.

Q: What’s the typical lead time for custom plastic parts?

A: For projects similar to this dishwasher basket:

Mold manufacturing: 35-45 days
First article samples: 3-5 days after mold completion
Mass production: 10-20 days for 5,000-10,000 units
Total: 50-70 days from sample approval to delivery

Rush services available: 25-30 day expedited mold making with premium service.

Q: What’s your minimum order quantity?

A: Standard MOQ is 1,000 pieces. We can accommodate 500-1,000 pieces for market testing, seasonal products, or replacement parts.

Q: Can you manufacture other home appliance parts?

A: Absolutely. Our experience includes:

Kitchen: Dishwasher components, refrigerator parts, coffee makers, food processors
Other appliances: Vacuum cleaners, air purifiers, small appliance housings and so on.

We maintain ISO 9001:2015, FDA compliance, and RoHS/REACH certifications.

Why Choose Rayleap

Complete Process Ownership

Single point of contact from sample to delivery

ISO 9001:2015 certified facility

English-speaking project managers

Technical Expertise

25+ years in home appliance plastic parts
In-house engineering for DFM optimization
Advanced equipment: 10+ CNC machines, 30+ injection molding machines (80-2700 tons)

Flexible Production

MOQ: 1,000 pieces (lower than industry standard)

Scalable from prototype to high-volume

Rush orders: 30-day turnaround available

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