Mold Re-Engineering and Custom Knob Screw Innovation for Smart Medical Mobility Devices

This success story demonstrates how UJEN leveraged precision mold redesign, customized fastening engineering, and flexible manufacturing workflows to help a global medical-aid brand upgrade its smart walker system. Through internal mold restructuring, UJEN enabled a full transition from spring pull pin to ergonomic knob screw without rebuilding the tool, reducing cost and accelerating launch while achieving superior usability, safety, and product differentiation.

Client Background｜A Medical-Aid Brand Backed by a Fortune Global 500 Technology Group

The client belongs to a world-class ICT manufacturing group founded in 2001, recognized by Fortune Global 500 and Forbes Global 2000 rankings for its global footprint across Asia, Europe, and the Americas. The subsidiary specializes in developing high-performance smart mobility aids, integrating advanced sensing, ergonomic design, and durable mechanical systems. To upgrade its flagship smart walker, the brand sought a next-generation fastening mechanism for the handrail–base joint—one that combined intuitive use, structural stability, and modern aesthetics.

Design Challenge｜From Spring Pull Pin to Tool-Free Knob Screw—Under a No-New-Mold Constraint

Smart medical devices require intuitive operation, long-term durability, and reliability under daily adjustments. The fastening mechanism needed to deliver:

• Tool-free quick adjustment for users and caregivers
• High-strength structural performance for safety assurance
• Ergonomic grip and a refined appearance aligned with medical aesthetics

The initial version of the walker used a customized spring pull pin developed through UJEN’s earlier engineering support and mold fabrication. After market testing, however, the brand decided to adopt a more intuitive knob-screw locking mechanism. The challenge: whether the original mold—designed for an entirely different internal structure—could be re-engineered to produce a new knob screw without rebuilding a new mold.

This requirement placed high demands on UJEN’s precision engineering capability, mold-structure adaptability, and cost-efficient solution design.

UJEN Solution｜Precision Mold Re-Engineering and Custom Knob Screw Development

With forty years of expertise in precision mold design, CNC machining, and experimental engineering, UJEN collaborated closely with the client’s R&D team through multiple technical rounds and rapid prototyping. The final solution exceeded expectations:

Mold Internal-Structure Transformation

• Key Achievement： UJEN reconfigured the internal tool architecture of the original mold—built for a spring pull pin—into one capable of producing a completely new knob-screw design. No new mold was required.
• Value Delivered： This saved significant mold development cost and weeks of project time while demonstrating UJEN’s mastery of mold engineering flexibility and unconventional innovation.

Next-Generation Tool-Free Knob Screw

• Installation and adjustment time reduced by over 50%
• Ergonomic knob head for superior grip and intuitive operation
• Smooth, medical-grade surface finish with no sharp edges

High-Strength Mechanical Performance

• Alloy-steel screw core with professional heat treatment
• Stable long-term durability meeting medical device demands
• Consistent quality ensured through UJEN’s ISO9001 system

Results｜Enhanced User Experience, Higher Reliability, Stronger Market Position

The upgraded fastening system delivered measurable improvements:

• Significantly improved user accessibility： Intuitive tool-free operation earned strong positive feedback from users and caregivers.
• Increased product durability： Reduced maintenance cases and improved long-term reliability.
• Higher competitiveness： The refined design and improved functionality strengthened the brand’s presence in the premium medical-aid segment.

UJEN Insight｜Precision Flexibility for Medical-Grade Hardware Development

The client praised UJEN for its engineering depth, rapid response, and high customization capability. The success further reinforced UJEN’s reputation as a strategic partner for complex hardware transformations, mold redesign, and customized fastening components.

Whether you require knob screws, spring pull pins, adjustable handles, indexing mechanisms, or specialized fastening components—especially when facing mold modification challenges—UJEN provides end-to-end solutions from design, sampling, mold development or re-engineering, to scalable production.

With decades of manufacturing expertise and local R&D strength, UJEN helps global brands Add More product value and confidently Grip the Future.