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- Production Process
Phase 1: Candle Body (Shell) Manufacturing
The candle body is the core of the shell, which would make the product’s texture and realism.
Material: The polypropylene (PP), molded in one piece using an injection molding machine.
Injection Molding: With PP plastic granules heated and melted, then injected into a precision steel mold under high pressure. After cooling, a precisely shaped plastic candle body is obtained. Surface treatment is required to achieve a waxy texture.
Surface Treatment and Finishing: Make the candle body look more like a real candle.
Coloring – Cutting – Detail Sculpting: After this series of steps, the candle body is complete.
Phase 2: Electronic Mechanism (Functional Components) Preparation
Components: Depending on the product’s functional requirements, prepare LED lights (monochrome or multicolor), integrated circuit chips (for controlling the flashing pattern), battery contacts, switches, resistors/capacitors, etc. For advanced simulated flame models, magnets, electromagnetic coils, and lever mechanisms may also be included.
PCB Board: Micro-integrated circuits, resistors, and other components are mounted onto a printed circuit board (PCB) using surface mount technology (SMT). The assembled board will be wave soldered or reflow soldered to securely solder the components onto the PCB.
Functional Testing: Using a simple power supply and testing tools, the soldered board will undergo functional testing to ensure the LED lights function properly, the integrated circuit program runs smoothly, and the switch response is sensitive.
Third Stage: Final Testing and Packing
Final Assembly: The tested electronic components will be installed into the prepared hollow candle body. If the product is waterproof, sealant will be applied to the seams, and a silicone gasket will be used at the battery cover. The flame head will be positioned above the LED lights and protrude from the pre-drilled hole at the top of the candle.
Final Testing: The power switch, light modes, and remote control functions will be tested again by an external power supply to ensure they function correctly.
Visual Inspection: The candle body will be inspected to guarantee there is no scratches and damage, uniform assembly gaps, and a straight flame head.
Packaging and Warehousing: Products that pass final testing will be labeled (e.g., CE marks), packed and finally stored, ready for shipment to the European, American and all the other markets.
