Precision SPCC Enclosure with Blue Zinc Plating
Requirements:
A leading industrial automation supplier needed durable, corrosion-resistant enclosures . Their requirements included a low-volume initial run of 25 units, a robust SPCC construction, and zinc plating finish for both aesthetics and corrosion protection.
Material: SPCC
Surface treatment: Zinc plating
QTY: 25pcs for trial order
Additional requirements: Free of burrs, stains, and scratches.
Sheet metal process methods includes: Laser cutting, bending, PEM Fastener Installation & Welding, Polishing & Deburring, Zinc Electroplating
Manufacturing procedures
1. Laser Cutting:
Process: We utilized high-precision fiber laser cutting services to cut the SPCC sheets. This ensured clean, burr-free edges and exact dimensions for all flat patterns, maintaining perfect holes for components and fasteners.
Quality Check (QC): First-Article Inspection (FAI) was performed using digital calipers and optical comparators to verify all critical dimensions against the client's CAD model.
2. CNC Bending:
Process: The laser-cut blanks were formed on our CNC press brakes. Precision tooling and programming guaranteed accurate bend angles and consistent flange dimensions, crucial for the enclosure's final form and fit.
Quality Check (QC): Angle measurement tools were used to check every batch, ensuring repeatability across all units.
3. PEM Fastener Installation & Welding:
Process: PEM studs and nut inserts were precisely pressed into pre-punched holes to provide strong, threaded points for assembly. For structural seams, our skilled technicians performed MIG welding, followed standards and notes on drawing.
Quality Check (QC):Torque test to verify holding strength of all pressed PEM fasteners. Weld seams were visually inspected for consistency and penetration.
4. Polishing & Deburring:
Process:Polishing and deburring . This step was critical to achieve a smooth surface, essential for a uniform final plating and safe handling.
Quality Check (QC): A visual and tactile inspection confirmed the removal of all sharp edges and welding splatter.
5. Zinc Electroplating (Surface Treatment):
Process: The parts were sent to our trusted, certified plating partner for zinc electroplating following the specification.
Quality Check (QC): We verified the plater's certification and batch reports. Upon return, samples were tested for coating thickness and adhesion, and a 48-hour salt spray test was performed on a control sample to validate corrosion resistance.
The Result & Client Benefits
We delivered 500 perfectly finished SPCC enclosures with blue zinc plating on schedule. The client received:
Durability: The combination of SPCC and blue zinc plating provided a robust, long-lasting housing for sensitive electronics.
Aesthetic Appeal: The consistent, vibrant blue finish enhanced the professional look of their end product.
Precision Fit: Our multi-stage QC ensured all parts assembled seamlessly and met all dimensional specifications.
Cost-Efficiency: Our small-quantity manufacturing capability allowed the client to launch their product without the high cost of large-volume commitments.
