Case Study: Gore® Acoustic Vents for Smartphones

Learn how Gore helped a leading Chinese smartphone manufacturer fix a problem with their assembly line by developing an acoustic vent based on a new material. 

Case Study
Woman sitting on a bench in front of the ocean using her smartphone.

Challenge

Today, customers expect their mobile phones to be waterproof and to provide the best sound quality. A leading smartphone manufacturer was at risk of failing their customers in that basic regard: during the assembly process, the acoustic vents broke and reduced the sound quality of the device – with only three months left before mass production.

The manufacturer approached Gore to provide a more robust solution for a waterproof device with excellent sound quality. Gore went above and beyond to provide a suitable acoustic vent but also solve the problems during the assembly, thus facing time pressure to keep the production timeline.
 

Solution

Gore replaced the delicate foam layer in standard vents with a rubber-based material – a novelty in Gore’s portfolio. Although robust, it was more difficult to laminate than foam. But the engineers quickly found an answer to successfully apply the new material – relying on their efficient supply chain and their rapid development capabilities. The client benefited from Gore’s collaborative approach and dedication to cost control. Agile testing and sampling ensured the perfect balance between acoustic performance and cost efficiency.

Besides offering the right vent, Gore fixed the root cause of the problem: they investigated the high breakage during trial runs by recreating the failure with an air gun and traced it to the vacuum pick‑up nozzle. The remedy was to keep the existing vacuum setting but to reposition the nozzle to avoid further damage.

The Technology Behind the Solution: GORE® Acoustic Vents (for Smartphone Microphones)

“With the failure in the pick-up machine, the membranes disappeared – leaving no clue of what the root cause might be. Still, our team was able to find it, and we offered a solution to get the failure down to 0%.”

Kelvin TF Wei / Application Engineer at Gore

Gore’s customer‑centric tailoring delivered an acoustic vent with a rubber layer, which preserved the target acoustic response while improving robustness and cost efficiency. The rubber‑layer acoustic vents are engineered to strengthen assembly robustness and seal integrity without sacrificing sound quality. 

Their key benefits include:

  • Reliable protection: Durable rubber top layer resists assembly damage; breakage cut to 0%.
  • Design flexibility: Multiple hardnesses and tuned adhesives support wide compression and sealing.
  • Acoustic performance: Maintains foam‑level response; rapid 2‑day iterations confirmed target acoustics.
  • Automation‑ready: Die‑cut parts suit high‑volume pick‑and‑place; nozzle tweak eliminated pick‑up damage.

For specifications and more detailed information on installation, please visit Gore Acoustic Vents.

Result

The program delivered a fast, scalable fix that cut assembly‑induced failures while enhancing acoustics, thus ramping up from pilot to multi‑million‑unit mass production. 

  • Schedule secured: A large-volume program moved from concept to MP in just 3 months, with customers valuing the total solution now being expanded to more devices.
  • Acoustic performance: Matched – and in tests slightly beat – the incumbent; fast fixture loops delivered 2‑day reports.
  • Quality improved: Achieved 0% air leakage, stabilizing performance and improving yield.
  • Material breakthrough: Pivot to robust rubber, plus pick‑and‑place tweaks removed the failure mode; a win that will benefit other OEMs and customers in the future.
     

“We have developed the optimal solution for our customer. And we hope to roll out the implementation of rubber acoustic vents for the other customers’ benefit.”

Eric ZZ Chu / Field Sales Associate

FOR INDUSTRIAL USE ONLY 

Not for use in food, drug, cosmetic or medical device manufacturing, processing, or packaging operations.