Rapid Custom ManufacturingRapid Custom Manufacturing

Low Volume Manufacturing Aluminum Parts

Project Overview:

Manufacturing Process: CNC Machining
Material: Aluminum 6061-T6
Surface Finishing: Sanding, Anodizing Silver, Logo Silk-screening
Part Tolerance: ± 0.05 mm
Quantity: 200 Units
Lead Time: 20 Days

The customer was an America based company bringing innovative ideas into reality by designing products in home automation system and medical devices. This was the first time for customer to use Made in China to save production cost and time for their products that used to be made in Japan or South Korea. Customer visited our facility and had a meeting to stress the details and importance of quality back and forth, then proceeded with low volume production after approval of the prototype's quality.
CNC Aluminum Machining   Project Challenge:

Considering the thin wall thickness 1.0 mm and big dimensions (L×W×H) 260×160×8 mm, keeping size stability and preventing deformation during CNC milling was the key challenge for this project. To ensure consistently tight tolerance and reliable dimensions stability, two aluminum fixtures were milled to assist the low volume CNC milling, one for milling the outer surface and another for milling the side holes for buttons and USB.

Plaster powder was usually used instead of the custom fixtures to reduce prototype cost and time, this answered why tolerance of the low volume CNC parts was higher than the prototype one as well as the much shorter unit manufacturing time and lower unit price.
CNC Aluminum Milled PartsCNC Milled Aluminum Parts. Total 15 milling cutters were used for the whole milling process including tapping M1.4, cutter diameters ranged from 10 mm to 0.4 mm. The cutting lines on visual surface were removed manually by sanding and beadblasting before anodizing finish.
Aluminum Sanded and Anodized PartsThe Sanded and Anodized Silver Aluminum Parts. The anodizing finishing provided not only aesthetic feeling and corrosion resistance also the stronger adhesion to other coatings, such as the Logo silk-screening ink.
The Logo and Text Silk-screened Parts. To ensure the strong adhesion of the Logo and Text ink to the parts, hardening agent was mixed to the silk-screening ink and then the silk-screened Logo and Text ink was heated to 100 centigrade degree around 10 minutes in oven.
Assembly TestingThe Assembly Testing with Middle Frame Part Made by ABS+PC Injection Molded. The free assembly testing service from us helped find the possible defect in advance and customer could benefit it to save time.

Packaged Parts for Shipping by Air Express. Before packaging the parts for shipping, every part went through the quality inspection in tolerance, shape stability and surface finishing, the substandard ones were sorted out for repair or remaking, the photos and quality inspection report were provided as per request.

What Customer Said to US:

"It is comfortable to work with you, all of us are happy for the awesome job you did, this will help us to grow bigger and faster, we will send you more works in future, please keep the consistent quality and service".
  Packaged Parts for Delivery