Case Study: A Complex Assembly Made Simple
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Case Study: A Complex Assembly Made Simple
In the competitive world of manufacturing, the true test of a supplier isn't just producing simple parts, but mastering complex, multicomponent assemblies. A recent project with a client in the robotics sector perfectly illustrates how our integrated approach transforms intricate challenges into seamless production successes.
The client approached us with a critical challenge: a sophisticated sensor housing assembly requiring the integration of five distinct components. These included a primary 6061 aluminum housing, a stainless steel protective bracket, two different POM (Polyoxymethylene) insulating sleeves, and a custommachined brass connector. The hurdles were significant. Beyond the multimaterial compatibility (Aluminum, Steel, POM, Brass), the project demanded extremely tight tolerances (±0.05mm) on the main housing to ensure perfect sensor fitment, and all parts had to be anodized or plated to meet strict IP67 weatherproof standards. Sourcing and managing these components separately would have been a logistical nightmare for the client, leading to potential delays and quality inconsistencies.
Our "OneStop CNC machining" solution was the key to simplification. We took full ownership of the entire process. Our engineering team first conducted a Design for Manufacturability (DFM) analysis, suggesting subtle design tweaks to the POM sleeves that reduced machining time without compromising function. All components were then precisionmachined inhouse on our advanced 3, 4, and 5axis CNC mills and lathes. This centralized control guaranteed that the tolerances and surface finishes were consistently maintained across all different materials.
Postmachining, we managed the entire secondary process workflow. The aluminum housing received a black hardanodize, the stainless steel bracket was passivated, and the brass connector was nickelplated—all through our vetted network of surface treatment partners, which we managed and qualitychecked. Finally, the parts were kitted together and assembled in our clean room before being shipped as one complete, readytoinstall unit.
The outcome was transformative for the client. They received a 100% functional assembly, eliminating their supply chain coordination headaches and reducing their total project timeline by 40%. This endtoend service allowed them to focus on their core R&D, accelerating their product's timetomarket.
CNC machining
This case study underscores a vital lesson: for complex, multipart assemblies, partnering with a factory that offers integrated machining, finishing, and assembly is not just convenient—it's a strategic advantage. We don't just make parts; we deliver solutions, simplifying complexity and driving growth for our partners.
In the competitive world of manufacturing, the true test of a supplier isn't just producing simple parts, but mastering complex, multicomponent assemblies. A recent project with a client in the robotics sector perfectly illustrates how our integrated approach transforms intricate challenges into seamless production successes.
The client approached us with a critical challenge: a sophisticated sensor housing assembly requiring the integration of five distinct components. These included a primary 6061 aluminum housing, a stainless steel protective bracket, two different POM (Polyoxymethylene) insulating sleeves, and a custommachined brass connector. The hurdles were significant. Beyond the multimaterial compatibility (Aluminum, Steel, POM, Brass), the project demanded extremely tight tolerances (±0.05mm) on the main housing to ensure perfect sensor fitment, and all parts had to be anodized or plated to meet strict IP67 weatherproof standards. Sourcing and managing these components separately would have been a logistical nightmare for the client, leading to potential delays and quality inconsistencies.
Our "OneStop CNC machining" solution was the key to simplification. We took full ownership of the entire process. Our engineering team first conducted a Design for Manufacturability (DFM) analysis, suggesting subtle design tweaks to the POM sleeves that reduced machining time without compromising function. All components were then precisionmachined inhouse on our advanced 3, 4, and 5axis CNC mills and lathes. This centralized control guaranteed that the tolerances and surface finishes were consistently maintained across all different materials.
Postmachining, we managed the entire secondary process workflow. The aluminum housing received a black hardanodize, the stainless steel bracket was passivated, and the brass connector was nickelplated—all through our vetted network of surface treatment partners, which we managed and qualitychecked. Finally, the parts were kitted together and assembled in our clean room before being shipped as one complete, readytoinstall unit.
The outcome was transformative for the client. They received a 100% functional assembly, eliminating their supply chain coordination headaches and reducing their total project timeline by 40%. This endtoend service allowed them to focus on their core R&D, accelerating their product's timetomarket.
CNC machining
This case study underscores a vital lesson: for complex, multipart assemblies, partnering with a factory that offers integrated machining, finishing, and assembly is not just convenient—it's a strategic advantage. We don't just make parts; we deliver solutions, simplifying complexity and driving growth for our partners.