Customer Background
Customer: Ningbo Wangtong Lock Industry Co., Ltd.
Industry: Electronic lock manufacturing
Main soldering targets: Positive/negative electrode tabs, large-area copper foil
Soldering process: Lead‑free soldering at 380°C
Pain Points & Challenges
The customer had been using a certain brand's 911G series soldering tips and suffered from persistent issues:
Frequent tip perforation and low durability: Monthly consumption reached as high as 65 pieces.
Root cause analysis: The customer's soldering targets are mostly large-area copper foils, which dissipate heat rapidly. This caused insufficient heat transfer at the tip. Raising the temperature to compensate only accelerated corrosion of the plating layer, leading to perforation and cold solder joints.
The soldering scenario in question
Our Solution
Problem identification: Our technical engineer conducted on‑site temperature measurements and discovered a 30°C temperature drop between the set temperature and the actual tip temperature – the direct cause of poor solder flow and reduced tip life.
Process optimisation: We adopted high‑thermal‑conductivity C1100 oxygen‑free copper as the base material and fine‑tuned the plating density to ensure rapid temperature recovery, perfectly matching the actual soldering environment.
Parameter adjustment: Recommended reducing the soldering frequency appropriately, allowing the tip's built‑in thermal mass to complete each solder joint without over‑relying on constant high heat.
Operator training: Delivered a 15‑minute "Temperature vs. Service Life" micro‑training session to production line staff, correcting the common misconception that "higher temperature is always better."
Quantified Results
| Parameter | Original Tip | Our Tip | Improvement |
|---|---|---|---|
| Soldering temperature | 380°C | 380°C | Unchanged |
| Average service life | 18,000 joints | 23,000 joints | 27% longer |
| Monthly consumption | 65 pieces | 50 pieces | 23% fewer |
| Monthly consumable cost | RMB 1,625 | RMB 950 | 41% saved |
Customer Testimonial
"We had been facing this problem for a long time. We approached five different suppliers, but none of them could resolve it. Then we found your company. After improving your manufacturing process and providing samples, you not only solved the issue but also boosted our production efficiency while lowering manufacturing costs. That's what we call real professional expertise from a manufacturer."
— Mr. Tuo, Production Supervisor, Ningbo Wangtong Lock Industry Co., Ltd.
