PRODUCTION PROCESS

Each shuttlecock requires 16 nearly identical feathers to ensure consistent flight. To achieve this, a specialized sorting machine equipped with 26 sensors automatically scans and classifies feathers based on size, shape, thickness, and curvature.

A punching machine prepares the cork base with 16 evenly spaced holes. A worker then manually feeds each feather into a semi-automated machine, which inserts it into the holes with precise alignment and consistent spacing.

After insertion, each shuttlecock is carefully inspected. Damaged feathers are repaired or replaced, and the shape is checked for symmetry. Workers may also adjust feather angles to ensure proper structure before gluing.

Once the feather positions are finalized, each shuttlecock is placed into a gluing machine. The machine applies a thin, continuous line of adhesive along the full length of each feather, bonding it securely to the cork base. This reinforces the feather placement and ensures stability during play.

After gluing, the shuttlecocks are left to dry in a controlled environment. This allows the adhesive to fully cure, locking the feathers in place and preparing the shuttlecocks for the next shuttlecock production stage.

To further reinforce the structure, each shuttlecock is placed into a specialized sewing machine. The machine wraps two rows of thread tightly around the feathers, securing them firmly together. A worker then ties off the thread and trims any excess to prevent unraveling during use.

After stitching, workers check each shuttlecock for feather alignment, stitching tightness, and overall build quality. Each shuttlecock is then placed into a wind tunnel testing machine to verify that its rotation speed and balance meet aerodynamic standards.

A fixture holds each shuttlecock in place, while an automated gluing arm applies adhesive along the stitched threads. This secures the wrapping and reinforces the structure, preventing the threads from loosening during play.

A machine applies tape around the cork base of each shuttlecock. This tape serves as an identifier during play and gives the shuttlecock a clean, finished appearance.

Each shuttlecock undergoes a final flight test to verify its performance. A robotic arm strikes the shuttlecock to observe its trajectory, rotation, and stability in flight. Only shuttlecocks that meet the required standards proceed to packaging.

Qualified shuttlecocks are packed into tubes, typically 12 per tube, for storage and shipment. The tubes are then boxed and prepared for delivery to retailers, distributors, or customers worldwide.