Shieldon has upheld 27 years of excellence in delivering OEM and ODM manufacturing solutions for knives, multi-tools, and outdoor equipment. As the global market evolves rapidly, the demand for precision engineering, functional innovation, and sustainable practices in multi-tool manufacturing grows ever more critical. This guide unpacks Shieldon’s advanced multi-tool production process, detailing how each step—from handle material selection to semi-finished product inspection—ensures superior quality, reliability, and customization flexibility.

1. Handle Manufacturing: Material Selection, Mold Development and Forming Technologies

The handle is the user’s primary interface with a multi-tool; it demands ergonomic comfort, structural strength, and corrosion resistance. At Shieldon, handle manufacturing draws on cutting-edge materials and precision forming technologies tailored to both metal and non-metal substrates.

1.1 Material Selection and Pre-treatment

Choosing the right material base for the handle is pivotal for weight reduction, durability, and user experience.

Base Material Types

• Metals:
  • 6061-T6 Aerospace-grade Aluminum: Renowned for its lightweight properties and excellent corrosion resistance, ideal for tactical and portability-focused tools.
  • 17-4PH Stainless Steel: Offers a high strength-to-weight ratio and outstanding mechanical properties.
  • TC4 Titanium Alloy: Provides exceptional corrosion resistance and biocompatibility. The integration of titanium alloy or titanium composite materials reduces handle weight by approximately 30% while simultaneously increasing strength by up to 50%, meeting the exacting demands of military and aerospace standards.
• Non-Metals:
  • Glass Fiber Reinforced Nylon (GF50%): Balances cost-effectiveness with enhanced durability and chemical resistance.
  • Carbon Fiber-PEEK Composites: Exhibits superior high-temperature resistance and mechanical strength, suitable for high-end multi-tools requiring premium performance.

Pre-treatment Process

To maximize coating adhesion and ensure long-term durability, different pre-treatment workflows are employed depending on the base material:

• Metals: The process starts with ultrasonic degreasing to remove oils and contaminants. This is followed by acid pickling activation to prepare the metal surface, and a final passivation treatment to form a thin oxide layer that improves corrosion resistance and coating bonding.
• Non-Metals: Plasma surface treatment raises the surface energy level to ≥42 mN/m, enhancing wettability and adhesion for subsequent coatings or paints. This clean, activated surface ensures robust bonding and durability under extreme conditions.

1.2 Core Technologies for Mold Development

Precision molds are the cornerstone of consistent, high-quality handle production. Shieldon leverages advanced engineering tools and equipment to guarantee mold accuracy and performance.

• 3D Reverse Engineering: Utilizing the GOM ATOS Q blue light scanner, Shieldon captures the finest details of prototype models or samples. This ensures dimensional fidelity and supports rapid tooling iterations. Tolerance grades comply with ISO 2768-mK standards, facilitating stringent dimensional control.
• Moldflow Analysis: Employing hot runner synchronous control technology, Shieldon conducts detailed simulations to optimize molten material flow and cooling balance. Achieving a Moldflow filling balance ≥95% minimizes defects like sink marks, weld lines, and air traps during molding.
• Mold Machining: The Makino V80S 5-axis high-speed milling machine is used to fabricate mold cavities. Mirror EDM finishes achieve surface roughness as fine as Ra ≤ 0.1μm. Laser machining precision meets aerospace-grade accuracy of ±0.005mm, ensuring intricate handle features and tight tolerances.

1.3 Upgraded Forming Processes

With molds ready, forming the handle requires different approaches based on the chosen material to ensure structural integrity and efficiency.

Metal Handle Stamping

• Servo Hydraulic Fine Stamping: Punching clearance is tightly controlled to within 5% of the sheet thickness. This precision reduces burr formation and improves dimensional accuracy. The bright shear zone—a measure of cut edge quality—is maintained at ≥85%, critical for subsequent finishing and assembly.
• Progressive Die Design: This innovation integrates multiple processes—punching, flanging, embossing—into a single continuous stroke. Up to five forming steps are completed simultaneously, improving throughput and repeatability while reducing costs and waste.

Non-Metallic Injection Molding

• Microcellular Injection Molding (MuCell): This patented technology introduces microbubbles into molten polymers, reducing material usage and weight by approximately 15%. Dimensional stability is tightly controlled at ±0.02mm, which is essential for precision fit in multi-tool components.
• In-Mold Decoration (IMD): IMD integrates visual features such as brand logos and textured surfaces directly into the molding process. This enhances abrasion resistance to ≥5,000 wear cycles and delivers vivid, durable aesthetics without secondary printing.

1.4 Precision Machining and Surface Treatment

Even after forming, handles require precision machining and specialized surface treatment to meet functional and aesthetic specifications.

• Tapping: Threads such as M6×1 are produced using extrusion taps, which plastically deform material rather than cutting, resulting in stronger threads. All threads undergo 100% go/no-go gauge inspection and torque testing, requiring a minimum torque resistance of 8 N·m.
• Chamfering: Edges are polished using magnetic polishing with ceramic media sized 0.3–0.5mm, achieving edge radii of R0.2 ±0.05mm to eliminate sharp edges and improve tactile comfort.
• Drilling: Deep hole drilling with diameters of Φ3±0.01mm ensures critical holes for pivot pins and fasteners meet coaxiality tolerances ≤0.03mm, essential for smooth mechanical operation.
• Surface Treatment: Micro-arc oxidation (MAO) coatings provide a hard, wear-resistant ceramic layer approximately 30μm thick, achieving hardness of HV1500. Salt spray resistance exceeds 1,000 hours (ASTM B117), ensuring exceptional corrosion resistance in harsh environments.

2. Functional Component Manufacturing: Blades, Transmission Gears, Locks, and Bearings

The multi-tool’s performance hinges on the quality of its internal components. Shieldon focuses on material innovation, state-of-the-art manufacturing methods, and rigorous testing for blades, gears, locking mechanisms, and bearing systems.

2.1 Blade Components: Material Science and Edge Formation

Material Science

• Selección de acero premium: CPM-S90V powder metallurgy steel is the material of choice for high-performance blades. This steel offers exceptional wear resistance and toughness.
• Coating Technology: The proprietary Z-FiNit coating reduces the friction coefficient to ≤0.15, significantly extending tool life—up to three times the industry average.
• Heat Treatment: Vacuum oil quenching followed by cryogenic treatment (-196°C for 24 hours) optimizes hardness and microstructure. Target hardness is HRC62 ±0.5, balancing edge retention with resistance to brittle failure.

Edge Formation

• 5-Axis Laser Sharpening: Using a laser wavelength of 1,070nm and 800W power, edges are ground with an angle tolerance of ±0.1°, ensuring consistent sharpness and bevel geometry.
• Electrochemical Honing: Electrolyte solution of sodium nitrate (NaNO3) polishes edges to a radius ≤5μm, achieving scalpel-level sharpness that improves cutting performance and user safety.

2.2 Transmission Gear Set: Precision Forming and Machining

• Forming via Metal Injection Molding (MIM): The gear base material is formed with densities ≥7.8g/cm³ and oxygen content ≤0.1%, ensuring mechanical strength and fatigue resistance.
• Vacuum Sintering: Conducted at 1,350°C for 6 hours, sintering refines grain structure meeting ASTM grain size grade 10, balancing hardness and toughness.
• Precision Machining: Gear hobbing and shaving are performed to DIN 3962 grade 4 accuracy, achieving tooth surface roughness Ra 0.4μm. A digital twin system constantly monitors machining parameters, while AI vision inspection rejects defective parts with ≥99.99% accuracy, ensuring consistent quality.

2.3 Locking Mechanism: Material Innovation and Precision Manufacturing

• Material Base: Maraging steel is selected for its ultra-high yield strength (~2,000MPa), providing robust lock performance.
• Surface Reinforcement: Laser cladded tungsten carbide-cobalt (WC-Co) coatings (~0.2mm thick) improve wear resistance on critical contact surfaces.
• Manufacturing: Slow wire EDM using Φ0.03mm molybdenum wire achieves ±0.003mm accuracy necessary for tight locking fits.
• Assembly Testing: Unlocking force is measured with 3D force sensors, targeting a range of 15-20N for reliable, user-friendly operation.

2.4 Bearing System: Structural Design and Manufacturing Excellence

• Self-Lubricating Design: Bearings incorporate an inlaid graphene-copper composite, significantly reducing friction and maintenance needs.
• Dustproof Structure: The bearing design features dual-lip sealing rings combined with labyrinth grooves to prevent dust ingress, enhancing longevity in harsh environments.
• Manufacturing Process: Ceramic balls undergo hot isostatic pressing (HIP) sintering achieving roundness ≤0.1μm for smooth rotation.
• Cage Formation: Selective Laser Melting (SLM) produces lightweight hollow titanium alloy cages, combining strength with reduced mass.

3. Semi-Finished Product Inspection: Ensuring Defect-Free Components

Shieldon’s inspection system integrates traditional quality control with intelligent automation to guarantee that all components meet or exceed international standards before assembly.

3.1 Modern Inspection Process: Full Inspection and Intelligent Sorting

• Dimensional Measurement:
  Sampling with digital calipers and projectors is complemented by automated 3D blue light scanning using GOM ATOS equipment. The system verifies adherence to ISO 2768-mK tolerance standards, ensuring precision in complex geometries.
• Functional Testing:
  Both manual random testing and fully automated multi-station test benches simulate over 5,000 operation cycles, assessing durability and mechanical reliability per IEN ISO 5743 standards.
• Surface Defect Detection:
  Visual inspection is augmented by deep learning machine vision systems capable of detecting defects with ≥99.9% accuracy, aligned with IASTM F2982 protocols.
• Material Verification:
  Hardness testers sample components for mechanical property confirmation, while handheld XRF spectrometers conduct rapid elemental composition analysis to verify alloy integrity, following IASTM E1621 guidelines.
• Resistencia a la corrosión:
  Components undergo salt spray (ASTM B117) and cyclic corrosion testing (CCT) lasting 1,000 hours to confirm resistance to environmental degradation.

3.2 Newly Added Critical Inspection Items

• Stress Distribution Testing:
  Photoelastic analyzers detect residual stresses within components, preventing deformation during assembly and service. Stress concentration factors are maintained ≤1.8, referencing ASME BPVC standards for structural safety.
• Microstructure Analysis:
  Metallographic microscopes examine grain sizes post heat treatment, ensuring blades meet or surpass ASTM grade 10 microstructural requirements for toughness and hardness.
• Dynamic Balance Testing:
  Rotating parts such as gear sets are dynamically balanced with residual imbalance corrected to ≤0.5g·mm/kg, minimizing vibration and noise during operation.

4. Final Assembly: Precision Integration and Functional Validation

The assembly phase synthesizes all components into a seamless multi-tool, demanding meticulous alignment, lubrication, and mechanical calibration.

4.1 Pre-Assembly Debugging

Key moving parts including springs and bearings undergo pre-assembly testing to verify smoothness and proper interaction before full assembly. This step reduces rework and ensures early detection of potential issues.

4.2 Riveting and Screw Fastening

The handle and internal tools are joined using a combination of pneumatic rivet guns and servo electric press riveting, monitored by acoustic emission sensors that ensure riveting forces deviate no more than ±3% from target values. Fasteners are torque-calibrated using CNC pulse tightening systems, guaranteeing repeatability within ±1%, preventing loosening or over-tightening that could impair functionality.

4.3 Lubrication Treatment

Silicone-based waterproof greases are manually applied to bearings and shafts, with additional oil immersion under vacuum and micro-dosing sprays to achieve an oil film thickness of 5±0.5μm. This treatment assures optimal lubrication and corrosion resistance throughout the tool’s life.

4.4 Scientific Assembly Sequence and Laser-Assisted Positioning

Assembly workflows combine manual trial assembly with six-axis robotic simulations enabled by digital twin systems, achieving simulation accuracy of ±0.01mm. Shieldon’s new Laser-Assisted Positioning (LAP) system projects real-time component placement guidelines onto assemblies with ±0.05mm precision, meeting aerospace-grade assembly standards and significantly reducing human error.

4.5 Functional Testing Matrix

• Opening and Closing Durability: Automated test benches cycle tools through 50,000 operations compliant with MIL-STD-810G, confirming structural integrity and smooth action.
• Locking Strength: Hydraulic progressive loading tests apply forces up to 200N, verifying locking mechanisms meet ANSI/ASSE B30.26 safety standards.
• Dust and Water Resistance: IP67-grade chambers simulate extreme environmental exposure, confirming ingress protection for long-term reliability.
• Ergonomics: Pressure distribution gloves analyze handle comfort and grip stress, ensuring compliance with ISO 9241 ergonomics guidelines.

4.6 Environmental Simulation Tests

• Temperature Shock: Components endure ten cycles between -40℃ and +85℃, per MIL-STD-883, validating thermal shock resistance.
• Dust Exposure: Quartz sand particles (20-100μm) blown at 8 m/s for 4 hours test the dustproofing effectiveness of seals and interfaces.

5. Inspection: Final Quality Assurance Before Shipping

Comprehensive inspection ensures the tool’s safety, performance, and compliance with international standards.

5.1 Functional Testing

• Blade Cutting Test: Tools must cleanly slice standard ropes to verify cutting performance.
• Tool Durability: Major components like the main blade are cycled open and closed 500 times without failure.

5.2 Environmental Simulation Tests

• Salt Spray Test: Accelerated corrosion tests simulate humid, salty environments to ensure rust resistance.
• High/Low Temperature Cycling: Repeated cycles from -20℃ to 60℃ confirm dimensional stability and operational reliability.

5.3 Safety Testing

• Edge Sharpness Detection: Non-cutting edges are inspected for burrs or hazards.
• Locking Mechanism Strength: Loads are applied to verify tools remain securely locked when deployed, preventing accidental closures.

5.4 Certification System Enhancement

Shieldon’s manufacturing adheres to multiple globally recognized certifications:

• ISO 9001:2015: Full-process quality control system.
• MIL-STD-810G: Military-grade reliability for durability and environmental testing.
• TÜV Certification: German safety certification ensuring anti-pinch design and user safety.

6. Laser Marking: Durable, Precise Branding and Compliance

Shieldon applies advanced laser marking technology to ensure permanent, crisp identification and regulatory compliance.

• Basic Markings: Brand logos, model numbers, steel grades (e.g., “CPM-S30V”), and product names (“The Warrior”) are marked following approved templates with precision matching prototypes.
• Compliance Marks: CE marks and mandatory safety warnings such as “Keep Away from Children” are included when applicable.
• Material-Specific Techniques:
  • Titanium and Stainless Steel: Fiber laser marking produces wear-resistant engravings 0.05–0.1mm deep.
  • Coated Surfaces: UV laser marking preserves coating integrity while delivering high contrast.

7. Cleaning and Protection Treatment: Pristine Condition Guaranteed

7.1 Cleaning Standards

All post-production cleaning is performed in ISO Class 7 dust-free workshops (≤35,200 particles/m³). Residual oils and contaminants are verified using the FDA-compliant cotton swab wipe method, ensuring no visible residues remain.

7.2 Corrosion Protection

• Short-term: Products are wrapped in Vapor Corrosion Inhibitor (VCI) paper effective for up to 6 months, compliant with MIL-PRF-3420 standards.
• Long-term: A bio-based, heavy metal-free anti-rust oil is sprayed on components, meeting strict REACH regulations and offering enhanced protection during storage and shipment.

8. Customized Packaging: Protection and Presentation

Shieldon offers tiered packaging solutions tailored to client budgets and market positioning.

8.1 Tiered Packaging Solutions

• Economy Level: Double-wall corrugated color boxes made from FSC-certified paper with EPE shock-resistant inserts provide safe transport and eco-conscious appeal.
• Premium Level: Anodized aluminum alloy gift boxes with flocked liners and magnetic closures create a luxurious unboxing experience favored in high-end markets.

8.2 Standardized Accessories Included

Each package includes multilingual user manuals (English, German, French, Spanish, Japanese minimum) and a toolkit containing custom screwdriver bits matched to handle screws and a micro lubricant syringe for maintenance.

8.3 Anti-Counterfeiting Measures

Tamper-evident paper seals that void upon breaking and invisible UV anti-counterfeit codes visible only under special UV light maintain brand integrity and protect against counterfeits.

9. Cartoning and Label Management: Traceability and Logistics Efficiency

9.1 Packing Process

• Anti-Oxidation Packaging: Use of desiccants or vacuum-sealing prevents moisture-related corrosion.
• Accessory Compartmentalization: Manuals, warranty cards, and spare parts are organized into designated compartments for ease of assembly by end-users.
• Traceability Labeling: QR-coded labels on each inner box enable quick access to production batch data and QC inspector IDs, supporting quality audits and recalls if necessary.

9.2 Standardized Carton Specifications

• Inner Box: Designed for single tools weighing ≤2kg, size approximately 200×100×30mm.
• Middle Carton: Holds 10 inner boxes, constructed from E-flute corrugated cardboard with compression resistance ≥400kg, tested to ISTA 3A standards.
• Outer Carton: Contains 10 middle cartons per pallet with fumigated wooden pallets marked per IPPC standards to comply with international shipping regulations.

9.3 Smart Labeling System

QR codes link to comprehensive batch reports, QC certifications, and material certificates. For air shipments, “Magnetized Material” hazard labels are affixed in accordance with IATA regulation 902.

10. Shipping: Flexible, Reliable Global Logistics

10.1 Upgraded Logistics Services

• Air Freight: Priority door-to-door delivery with DHL/FedEx within 7 days for shipments over 21kg; temperature control maintained between 15°C and 25°C.
• Sea Freight: Options for Full Container Load (FCL) or Less-than-Container Load (LCL) with trade terms including Delivered Duty Paid (DDP) or Delivered At Place (DAP).
• Rail Freight: China-Europe Railway Express from Xi’an to Hamburg offers approx. 18-day transit with GPS tracking for real-time shipment monitoring.

10.2 Customs Documentation Package

All shipments include commercial invoices, packing lists, Certificates of Origin, and Material Safety Data Sheets (MSDS). Optional documents, such as EU CE Declarations and US FCC Compliance certificates, are provided as required by clients or destination countries.

10.3 Insurance Options

• Basic Insurance: Covers 110% of CIF value, protecting against common transport risks.
• Special Insurance: Available for war risk and strike risk coverage, recommended for shipments to regions such as the Middle East and Latin America.

11. Environmental Disclosure and Sustainability Commitment

Shieldon’s commitment to environmental stewardship is central to its manufacturing philosophy.

11.1 Wastewater Treatment

CNC machining emulsion fluids undergo demulsification and biological treatment processes to meet GB8978 discharge standards. Heat treatment workshops are equipped with activated carbon adsorption and catalytic combustion systems to comply with strict EPA emissions regulations.

11.2 Full-Chain Environmental Certification

Packaging materials contain less than 5% plastic and achieve recyclability rates over 90% by replacing EPE foam with honeycomb paper where feasible. Each batch shipment includes a carbon footprint report detailing transportation-related CO₂e emissions.

11.3 Social Responsibility Disclosure

Holding SA8000 certification, Shieldon ensures ethical labor practices including regulated working hours and fair wages. A Conflict Minerals Statement confirms no tantalum or tin sourced from conflict regions such as the Democratic Republic of Congo is used in products.

Conclusión

Shieldon’s multi-tool manufacturing process exemplifies a harmonious blend of advanced materials science, precision engineering, rigorous inspection, and sustainable production principles. From aerospace-grade handle materials and proprietary blade coatings to intelligent inspection and laser-guided assembly, every step is optimized to deliver multi-tools that perform flawlessly in the most demanding conditions.

This comprehensive process, combined with transparent communication, meticulous quality control, and responsible environmental practices, positions Shieldon as a trusted partner for global brands seeking excellence and innovation in multi-tool manufacturing.