Partnering with international brands｜Full-process solutions for high-precision switch panels
Project Background and Challenges
A client commissioned us to develop an L-shaped metal switch panel. Over 40 inspection items were required, each with extremely tight tolerances. In addition to precision control during stamping, the impact of subsequent powder coating must also be considered. This coating presents common challenges, such as uneven thickness and difficulty painting around corners.
In this project, we faced multiple challenges:
- Double tolerance control for stamping and painting:The dimensional accuracy after metal processing and surface treatment must be met at the same time
- Screw hole and stud shielding design:It is necessary to prevent powder paint from entering the hole while taking into account cost and processing efficiency.
- Paint hanging position:Ensure uniform painting to avoid the situation where small angles are difficult to paint
- Packaging protection:Avoid transportation damage and surface scratches
R&D history and technical solutions
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Precision control and size compensation
We consider the dimensional compensation of paint film thickness during the stamping die design stage, use data from multiple mold trials to find out the actual impact of film thickness on various dimensions, and directly incorporate the compensation value into the mold processing dimensions. -
Optimization of shielding spraying technology
After comparing the costs and effects of various spray-painting solutions, we finally selected a special material that is both heat-resistant and reusable. Although it requires special customization, it can effectively prevent powder paint from entering the screw holes and reduce long-term production costs. -
Paint hanging fixture design
By analyzing the product's center of gravity and stress points, a design was developed that maintains a stable hanging position during the paint baking and rotation process. Furthermore, the manufacturing process was optimized and cleaning was enhanced to ensure uniform painting of corners and edges. -
Packaging process improvements
During the initial drop test, we immediately discovered the problem. We immediately developed a special EPE mold to fix the panel in the slot and redesigned the internal structure of the carton to ensure zero displacement and zero scratches during transportation.
Final Result
- All inspection items passed customer acceptance at one time
- The paint surface is even, without any missing or paint running
- The packaging protection rate reaches 100%, and mass production and shipment have zero scrap
- The customer incorporates this process standard into the subsequent product development plan for the same series
Our R&D spirit
The switch panel project, while seemingly simple, presents a complex challenge requiring meticulous attention to detail. From mold design to surface treatment, jig development, and packaging optimization, we invested significant time and repeated testing to ensure that each product met the requirements for functionality, aesthetics, and mass production stability.
