MANUFACTURING
Manufacturing Process Overview
Precision Casting
Process Description
Precision casting is a high-precision metal processing technique, especially suited for producing complex-shaped parts with high surface smoothness requirements. This process typically uses the lost-wax method, where a wax model of the part is created, covered with refractory material to form a mold, and then the wax is melted away and replaced with molten metal. Once cooled, the part takes its final shape. This process achieves high dimensional accuracy and allows for the production of parts with intricate details.
Applications
Precision casting is particularly suited for mass production, as it maintains high precision while enabling efficient production processes. This technique is commonly used for producing metal parts that require high strength and durability, such as connectors and brackets in outdoor gear.
Advantages
- High Precision: Precision casting can achieve dimensional accuracy of ±0.05mm, making it ideal for producing complex-shaped parts.
- High Surface Smoothness: The surface of cast parts is very smooth, often eliminating the need for additional polishing.
- Suitable for Mass Production: This process allows for mass production while maintaining high precision, reducing production costs.
Applicable Materials
- Aluminum Alloy
- Stainless Steel
MFJ 3D Printing
Process Description
MFJ (Multi Jet Fusion) 3D printing is a high-precision additive manufacturing technique suitable for producing complex metal parts. This technology works by melting and fusing metal powder layer by layer to form parts. With layer thicknesses as fine as 0.08-0.1mm, MFJ 3D printing is ideal for the rapid production of small-batch, high-precision parts.
Applications
MFJ 3D printing is ideal for producing parts with complex internal structures, especially shapes that are difficult to achieve with traditional methods. This technology is particularly well-suited for creating lightweight parts, such as brackets and connectors in outdoor gear.
Advantages
- High Precision: With layer thicknesses as fine as 0.08-0.1mm, it can achieve very intricate details.
- Flexible Internal Structure Design: MFJ 3D printing allows for hollow structures, reducing weight while maintaining strength.
- Suitable for Small-Batch Production: This technology is particularly suited for the rapid production of small-batch, high-precision parts, shortening product development cycles.
Applicable Materials
- High-Performance Nylon
- Stainless Steel
FDM 3D Printing
Process Description
FDM (Fused Deposition Modeling) 3D printing is a common additive manufacturing technique primarily used for rapid prototyping of plastics and carbon fiber composites. The process involves melting plastic material and layering it to form parts. With layer thicknesses typically ranging from 0.1-0.3mm, FDM is ideal for early-stage product validation and the production of non-load-bearing parts.
Applications
FDM 3D printing is mainly used for prototyping and non-load-bearing parts, such as plastic buckles and brackets in outdoor gear. Its low cost makes it ideal for rapid design iterations.
Advantages
- Low Cost: FDM 3D printing has relatively low material and equipment costs, making it suitable for rapid prototyping.
- Rapid Iteration: Due to its fast production speed, FDM 3D printing is ideal for early-stage design validation.
- Material Variety: This technology can use a variety of plastics and composites, adapting to different design needs.
Applicable Materials
- Engineering Plastics
- Carbon Fiber Composites
Multi-Axis CNC Machining
Process Description
Multi-axis CNC machining is a high-precision metal processing technique suitable for producing precision parts with complex surfaces. This technique uses multi-axis CNC machines to cut and shape materials, allowing for the creation of intricate geometries. With machining accuracy up to ±0.02mm, this method is ideal for manufacturing high-performance outdoor gear.
Applications
Multi-axis CNC machining is suitable for producing parts that require high precision and complex shapes, such as brackets, connectors, and frames in outdoor gear. This technique ensures consistency and stability in every part, guaranteeing high product quality.
Advantages
- High Precision: Multi-axis CNC machining can achieve high precision of ±0.02mm, making it ideal for precision parts.
- Complex Shape Processing: This technique can process complex geometries, meeting design requirements.
- High Stability: Multi-axis CNC machining ensures consistency and stability in every part, making it suitable for mass production.
Applicable Materials
- Aluminum Alloy
- Carbon Fiber
- Stainless Steel
Laser Cutting
Process Description
Laser cutting is a high-precision metal sheet cutting process that uses a laser beam to cut materials without physical contact. The kerf width can be as narrow as 0.15mm, and cutting accuracy can reach ±0.1mm. Laser cutting is especially suited for producing finely cut panels and structural components.
Applications
Laser cutting is widely used for precision cutting of metal sheets, making it ideal for producing panels, frames, and other structural components in outdoor gear. Since laser cutting does not require contact with the material, it ensures smooth and even cutting edges.
Advantages
- High Precision: Laser cutting can achieve high precision of ±0.1mm, making it suitable for producing fine parts.
- Non-Contact Cutting: Laser cutting does not require contact with the material, ensuring smooth and even cutting edges.
- Suitable for Complex Shapes: This technique can cut complex shapes, meeting design requirements.
Applicable Materials
- Aluminum Alloy
- Stainless Steel
Surface Treatment
Anodizing
Anodizing is a surface treatment process commonly used for aluminum alloys, where an electrochemical reaction forms a 10-25μm oxide layer on the surface. This oxide layer enhances the corrosion resistance and surface hardness of the aluminum, and it can be offered in various colors to improve the product’s appearance.
Applications
Anodizing is suitable for aluminum parts that are exposed to outdoor environments for long periods, such as brackets and frames in outdoor gear. This surface treatment enhances the wear resistance of aluminum, making it ideal for long-term outdoor use.
Advantages
- Enhanced Corrosion Resistance: Anodizing significantly improves the corrosion resistance of aluminum, making it suitable for outdoor environments.
- Increased Surface Hardness: The oxide layer increases the surface hardness of aluminum, enhancing its wear resistance.
- Multiple Color Options: Anodizing offers various color options, improving the product’s design aesthetics.
Applicable Materials
- Aluminum Alloy
Powder Coating
Powder coating is a surface treatment process commonly used for aluminum, titanium, and stainless steel, forming a 40-60μm protective layer on the material’s surface. This enhances the product’s appearance and durability. Powder coating offers various color options and provides excellent weather and corrosion resistance.
Applications
Powder coating is suitable for outdoor gear that requires high durability and aesthetics, such as brackets, frames, and connectors. This surface treatment enhances the product’s corrosion resistance and weather durability, making it ideal for parts exposed to outdoor environments for long periods.
Advantages
- Enhanced Durability: Powder coating forms a protective layer on the material’s surface, enhancing the product’s durability.
- Multiple Color Options: Powder coating offers various color options, meeting different design needs.
- Excellent Weather Resistance: Powder coating provides excellent weather resistance, making it suitable for parts exposed to outdoor environments for long periods.
Applicable Materials
- Aluminum Alloy
- Titanium Alloy
- Stainless Steel
