I. Overview of the Customization Process
1.Requirements Analysis Phase
● Technical parameter matching: Accurately collect product dimensional tolerances (±0.1mm~±1mm), material thickness (0.5mm~20mm), and mechanical property requirements (tensile strength, yield strength, etc.).
● Environmental assessment: Analysis of operating conditions such as temperature range (-40℃~200℃), corrosion level, vibration and shock.
● Bulk Demand Confirmation: Clarify the trial production quantity (1-50 pieces), mass production scale (500-100,000+ pieces), and delivery cycle requirements.
2.Design and development phase
● Structural optimization design: Based on the DFM (Design for Manufacturability) principle, process improvements are made to reduce stamping processes by more than 30%.
● Material selection recommendations: We provide performance comparisons and cost analyses for materials such as cold-rolled steel sheet (SPCC), stainless steel (304/316), and aluminum alloy (5052/6061).
● 3D Modeling and Simulation: 3D modeling was completed using SolidWorks/CATIA, and the structural strength and stability were verified through finite element analysis.
3.Process implementation stage
● Process design: Based on product characteristics, combine stamping (blanking, bending, stretching), laser cutting (accuracy ±0.05mm), CNC punching (turret mold), and other processing methods.
● Surface treatment solutions: We offer more than 10 surface treatment options, including spraying (powder/liquid), electroplating (zinc/nickel), anodizing, wire drawing, and sandblasting.
● Quality control system: Implementing a three-tiered quality control system including First Article Inspection (FAI), In-Process Quality Control (IPQC), and Final Quality Control (FQC).
II. Core Technological Capabilities
1.Precision machining capability
● Laser cutting: Maximum processing area 3000×12000 mm , minimum cutting hole diameter 0.5 mm
● CNC bending: Maximum bending length 12000 mm, minimum bending radius 0.8 times plate thickness, bending angle accuracy ±0.5°
● Welding processes include argon arc welding, carbon dioxide shielded welding, and spot welding, with weld strength reaching over 85% of the base material.
2.Materials processing technology
● Metal surface pretreatment: Degreasing, phosphating, passivation and other processes are used to improve coating adhesion (reaching level 0 in cross-cut test).
● Specialty material processing: Possesses experience in forming difficult-to-machine materials such as titanium alloys and magnesium alloys, and solves the problem of springback control.
● Heat treatment processes: Annealing, normalizing, quenching and other processes are available to meet different hardness requirements from HB150 to HB300.
3.Quality Inspection System
● Dimensional inspection: Equipped with precision inspection equipment such as a coordinate measuring machine (accuracy ±0.005mm) and a 2D image measuring instrument.
● Mechanical testing: Conducting material performance verification such as tensile testing, hardness testing, and impact testing.
● Environmental testing: Capable of performing environmental reliability verification such as salt spray testing (neutral/acidic), high and low temperature cycling, and vibration testing.
III. Typical Application Areas
1.Industrial equipment sector
● Automated equipment frame: 201/304 stainless steel frame with brushed finish and fingerprint-resistant process.
● Machine tool guard assembly: Made of 1.5-3mm cold-rolled steel plate, bent and then electrostatically sprayed (resistant to salt spray for 500 hours).
● Instrument housing: made of aluminum alloy, CNC machined and anodized, meeting IP65 protection rating.
2.New energy field
● Battery pack structural components: made of 5-series aluminum alloy, laser welded and CNC precision machined, with flatness controlled within 0.1mm/m.
● Charging pile casing: galvanized steel sheet + powder coating, UV resistant treatment, suitable for working environments from -30℃ to 70℃.
● Energy storage equipment cabinet: modular design with EMC electromagnetic compatibility protection structure.
3.Medical equipment field
● Medical instrument housing: made of 316L stainless steel, electropolished to meet GMP cleanroom requirements.
● Equipment support system: Lightweight aluminum alloy structure, load-bearing capacity up to 200kg, corrosion resistance rating C5-M
● Disinfection equipment cavity: thickness uniformity error ≤5%, weld seam smoothing treatment, no sanitary dead corners.
IV. Service Support System
1.Rapid response mechanism
● 24/7 support: Our technical team provides 24/7 online technical support.
● Urgent Order Processing: We offer a VIP fast track, with samples delivered in as little as 48 hours for urgent orders.
● Design Change Response: Complete design change assessment and process adjustment plan within 48 hours.
2.supply chain management
● Raw material security: Strategic partnerships have been established with Baosteel, Wuhan Iron and Steel, and other companies to ensure the stability of material quality.
● Flexible production capacity: Equipped with a 5,000㎡ production base, with a monthly capacity of over 10,000 units, and capable of rapid expansion.
● Logistics and distribution network: Six major warehousing centers nationwide, enabling delivery to major cities within 48 hours.
3.Value-added services
● Structural optimization recommendations: We offer free DFM analysis reports, which can reduce manufacturing costs by an average of 15-20%.
● Process Scheme Comparison: Provide 2-3 process schemes for comparison, including a comprehensive evaluation of cost, cycle time, and quality.
● After-sales technical support: Installation guidance, maintenance manual, and 3-year quality traceability service are provided.
V. Customized Case Studies
1.Automated production line framework
● Material: Q235B cold-rolled steel sheet (thickness 3-8mm)
● Process: Laser cutting + CNC bending + welding + powder coating (RAL7035)
● Features: Modular design, load-bearing capacity 500kg, flatness ≤1.5mm/m, meets ISO9001 quality standards.
2.New energy battery casing
● Material: 5052 aluminum alloy (1.2mm thick)
● Process: Stretch forming + laser welding + CNC machining + anodizing (natural color)
● Features: IP67 waterproof rating, 40% lighter than steel design, weld strength up to 120MPa
3.Medical equipment operating table
● Material: 304 stainless steel (1.5mm thick)
● Process: CNC punching + bending + welding + electrolytic polishing
● Features: Surface roughness Ra≤0.8μm, resistant to alcohol corrosion, meets medical device safety standards.
(Note: The actual solution will be provided with customized design and detailed technical parameters based on specific needs.)