In the high-stakes world of micro manufacturing, supplier selection is more than a procurement checkbox, it’s a strategic decision that can define a product’s fate in the marketplace. For companies navigating the challenges of miniaturization, regulatory complexity, and global supply chains, the difference between success and failure often lies not in a quote or a cleanroom, but in the depth of partnership between OEM and micro moulding specialist.
One real-world example highlights just how critical this relationship can be. A major consumer products company, struggling to meet demand and resolve persistent quality issues with a line of consumer inhalers, turned to Accumold with a problem that many suppliers would have walked away from. What followed was not just a contract, but a collaborative journey built on transparency, shared purpose, and above all, trust in Accumold’s ability to scale.
FROM STRUGGLING PRODUCTION TO STRATEGIC PIVOT
The client had been producing inhaler components at a large facility in Central USA. The product, while innovative, was plagued with manufacturing inefficiencies. Parts failed to fit consistently, aesthetics fell short, and internal processes (particularly around liquid leakage) posed serious health and safety risks. These defects weren’t occasional, they were endemic. At one point, nearly 40% of parts were failing at source.
The company had been working with multiple vendors, trying to coordinate tooling and assembly across several touchpoints. But the distributed model wasn’t delivering. It was messy, fragmented, and fundamentally unsustainable.
Recognizing the urgency of the situation, the company launched a supplier evaluation process. Every candidate claimed micro moulding expertise. Every website looked slick. But only one company offered the rare combination of credibility and confidence that mattered, and that was Accumold.
As Paul Runyan, VP of Sales & Marketing at Accumold, recalls, “They told us later that when they walked in our doors, they knew we could scale. It wasn’t just about what we said. It was the way we operated, the depth of our experience, and how clearly we could explain what success would look like.”
BEYOND CAPABILITY. A MINDSET OF SCALE
Most injection moulders at the time were offering single-cavity or, at best, four-cavity tooling solutions. Accumold proposed something radically different, five 16-cavity tools, producing high-precision, tightly toleranced components that had to be overmoulded around delicate lead frames.
The client was skeptical. Competitors flatly claimed such tooling density wasn’t feasible. But Accumold didn’t flinch. Backed by decades of in-house tooling expertise, an embedded team of technical veterans, and a culture built on solving hard problems, the company proved it could not only meet the requirement, but exceed it.
“We had engineers with over 30 years experience in micro moulding, ready to sit down with their team and walk them through our approach,” says Runyan. “That built credibility fast. And then we delivered.”
The success of the initial five tools led to an urgent expansion. Within six months, Accumold was asked to build 20 additional tools, qualifying each for production while maintaining its existing operations. The result? More than 150 million precision parts produced over the program’s lifecycle, on time, in spec, and with virtually no rework.
WHY MOST SUPPLIER EVALUATIONS MISS THE MARK
What makes this story particularly instructive is what it reveals about the supplier selection process itself.
Too often, OEMs evaluate vendors based on surface-level criteria such as quotes, certifications, equipment lists. But these indicators can obscure more than they reveal. As Brett Saddoris, Technical Marketing Manager at Accumold, says, “Glossy websites and marketing collateral often mask real capability gaps that only emerge once a project is underway.”
The truth is, real micro moulding capability can’t be faked. It shows up in how a company handles risk, how early they get involved in design, and how they manage scale. In this case, the client made the right call by focusing not just on cost, but on confidence, the confidence that Accumold could deliver under pressure.
FROM VENDOR TO STRATEGIC ALLY
Key to the success of the program was the nature of the relationship. This was not a transactional vendor engagement. It was a strategic partnership.
From day one, Accumold’s team worked shoulder to shoulder with the client’s technical staff. Design issues were surfaced and addressed collaboratively. New geometries were developed. Functional performance improved. Sink issues and leaking were eliminated. Components that had previously required design concessions were now moulded to spec, with precision and repeatability.
“They were open about their problems,” says Runyan. “They needed a solution. And they trusted us enough to let us help.”
That trust enabled not just quality improvements but system-wide efficiencies. By consolidating production under one roof (with integrated tooling, moulding, metrology, and packaging) the company eliminated the chaos of multi-vendor workflows. And with a supplier like Accumold that could demonstrate control, visibility, and speed, they finally had a platform to scale.
A BLUEPRINT FOR SUPPLIER SELECTION
What should other OEMs learn from this case?
- Evaluate Scalability Early. It’s not enough for a supplier to handle low-volume prototyping. Ask how they’ll scale when demand spikes, and how they’ve done it before.
- Ask for Technical Depth. Meet the people behind the process. Can they answer tough questions? Can they walk through tooling strategy, material selection, and gating plans in detail?
- Visit the Facility. Seeing is believing. A clean, well-run facility tells you more than a certification ever could. Observe how teams interact. Look for signs of vertical integration.
- Demand Collaborative Engagement. The best suppliers become part of your team. They don’t just quote, they question, advise, and invest in your success.
- Trust Takes Transparency. Look for suppliers who share process visibility. Accumold welcomed the client into its facility, held regular review meetings, and demonstrated progress on the floor. That transparency reduced anxiety and accelerated decision-making.
FROM ZERO TO 150 MILLION PARTS AND BEYOND
The outcome speaks for itself. In the first three years alone, the program scaled from zero to 25 million parts annually. Over time, it reached 150 million units, with fallout rates falling from 40% to under 1%.
This wasn’t just a manufacturing turnaround. It was a business transformation made possible by selecting the right partner, and working with them in the right way.
“At the end of the day, it wasn’t just about what we could make,” reflects Runyan. “It was how we made them feel. Confident. In control. And ready to win their market.”
For companies navigating the next wave of miniaturization, the lesson is clear. Don’t just buy micro moulded parts. Invest in a partner who can deliver them at scale, with precision, and with you (not for you) every step of the way.