Rapid Custom ManufacturingRapid Custom Manufacturing

Quality Appearance Prototype Manufacturing

Project Overview:

Prototype Manufacturing Process: CNC Machining
Prototype Material: Clear PMMA (acrylic), ABS, Standard Components
Surface Finishing: Mirror Polishing, Painting, Silk-screening, UV Coating
Quantity: 50 Units
Lead Time: 15 Days

This smart product was developed by a top brand internet company in China to improve the driving experience and safety by recording the driving information and alarming in case of emergency or error occured. Customer had high expectations for the finished prototypes and wanted them to perform and more importantly look as intended as possible, so surface finishing quality was the key challenge and a variety of surface finishing techniques were applied for the prototypes.
Project Challenge:

The multiple surface finishing techniques of painting, mirror polishing, silk-screening and UV coating for the prototypes required not only excellent surface finishing capabilities and experience, also the strong attention to each detail that would considerably affect the final finishing quality.

CNC Machining Prototyping:

CNC machining the top and bottom covers made of clear acrylic (PMMA) that would be mirror polished and UV coated. The smooth milled surface helped reduce hand polishing time also get tight tolerance. In addition, the cutting feed and speed of milling acrylic were different to milling the other plastics since its material properties of high brittleness.
  CNC Acrylic Machining
CNC Machined PMMA PartsCNC milled and semi-polished PMMA covers. It must be careful to hand polish the PMMA covers or they would probably crack or shatter by polishing as well as milling since their thin thickness and high brittleness.
CNC Milled ABS PartsCNC ABS milled and assembled middle frames consisting of two parts. PCB and other components were placed inside them. Surface finishings for middle frames were sanding, colors painting and silk-screening.
Rapid Appearance PrototypeThe finished prototypes. The final surface finishing UV coating to PMMA covers delivered the aesthetic high gloss appearance and also a good protection to prevent the clear PMMA covers from scratches.
Appearance Prototype ManufacturingThe majority of exported prototypes made in China were functional ones for fitting test, some prototypes were delivered without the final surface finishing that could be also well done together. At Honkia, our surface finishing quality was impressive and sometimes exceeded expectations.