Elf Blind Box

 
Various problems may be encountered during the production process; perhaps the production of this product goes smoothly, but there is no guarantee which product this “little elf” will appear in. Production is like opening a blind box, and there are always unexpected ‘surprises’ waiting for you! We always want to control the “little elf,” but it will leave some ‘room for play’ for itself.
 
We warmly welcome technical exchanges. Below we share two small cases.

Premium-finish smart lock panel

Technical challenge: How to solve the issues of inconsistent highlight edge width and poor highlight edge gloss?

The solution for inconsistent width:
Optimize the fixture by using precision holes for positioning.
Control the product height tolerance within ±0.01mm.
The solution for gloss issues:
Use high-speed equipment and simultaneously apply high-pressure air jets to the cutting area to reduce material buildup.

Challenging composite surface finish.

Technical challenge: Poor plating coverage occurs at hole openings after nickel-chromium electroplating process.
Our R&D team came up with a solution using auxiliary electrodes.
Principle of auxiliary electrodes:
Auxiliary electrodes were placed near the blind holes and entrances to guide the plating solution inside and ensure full coverage. They also balanced the current around the hole edges to prevent discoloration from uneven plating.
Implementation process:
We designed the electrodes’ shape, size, and position based on the product’s geometry, and carefully controlled plating parameters like voltage, current density, and time.

Production FAQ’s

What is the minimum wall thickness in millimeters for 3D printed products?

SLA：0.5mm；FDM：0.8mm；SLS：1mm；SLM：0.5mm.

3D printed solid products are expensive, how do you reduce costs?

The solid structure is optimized as a hollow cavity filled with a low-density support material.

Why do dimensional changes occur after anodizing of aluminum alloys?

During the pretreatment of aluminum alloy anodizing, acids or alkalis are used to degrease and chemically polish the surface. The chemical reactions between these acids/alkalis and the aluminum alloy will etch the surface layer.

Why is there an anomaly when using a spectrometer to test aluminum alloy material types?

Aluminum alloys are prone to the formation of dense oxide films (Al₂O₃) on their surfaces, which, if not thoroughly removed by grinding, can lead to inaccurate spectral excitation of the internal metal matrix, especially affecting the detection of trace elements (e.g., Mg, Si, Cu).

We are often asked by production often, what is the effective thread depth of this threaded hole?

1. It will lead to the assembly screws can not be completely screwed into the internal threads, or screwed to reveal too long screw tail, affecting the appearance and sealing.

2. Insufficient effective depth will lead to a reduction in the number of threads to be screwed in, and a decrease in the thread bearing capacity, which may lead to loosening and so on.

Why is it important for production to understand the environment in which the product will be used?

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