Overcoming Smart Bracelet Screw Corrosion: A Targeted Solution

 A smart bracelet we produced for a quality-focused Italian client recently faced a critical test: embedded metal screws began to rust during use. This issue, while seemingly small, compromised both the product's appearance and its long-term reliability.

Screw corrosion is a common challenge in wearables, typically resulting from a combination of factors:

Sweat Exposure: Frequent contact with skin exposes the screws to sweat, whose moisture and salts steadily corrode any weak points in the metal's protection.

Material Vulnerability: Previously used carbon steel screws with electroplated zinc were cost-effective, but the coating could be thin or easily damaged, allowing sweat to penetrate and cause rust.

Manufacturing Stress: The high heat of the molding process creates residual stress in the screws as the plastic cools, making the metal more prone to corrosion.

Implemented Solutions:

Improved Mold Design: We redesigned the mold to ensure the plastic encapsulates the screw more completely, minimizing its exposure to air and moisture.

Superior Screw Material: We replaced the carbon steel with AISI 304 stainless steel, which has a self-repairing protective oxide layer that resists sweat and corrosion.

Better Plastics: We switched to more stable, less moisture-absorbent engineering plastics to reduce the corrosive elements in the immediate environment.

We thank our client for their valuable feedback. This solution underscores our commitment to continuous improvement and delivering durable, high-quality products.