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Sheet metal processing offers critical advantages for drone component manufacturing, balancing structural integrity with minimal weight. Precision-formed metal parts ensure reliability in demanding flight conditions.
Key Material Considerations
- Aluminum Alloys (5052, 6061-T6, 7075): Dominant choice due to excellent strength-to-weight ratio, corrosion resistance, and machinability. Grades like 7075 offer near-steel strength.
- Stainless Steel (304, 316): Selected for high-stress components or extreme environments requiring superior corrosion resistance and toughness, though heavier than aluminum.
- Titanium Alloys: Used in high-performance or specialized drones for unparalleled strength-to-weight and corrosion properties, but at significantly higher cost and processing difficulty.
Core Processing Techniques
Laser Cutting: Delivers high-precision, complex shapes from thin to medium gauge sheets with minimal heat distortion, ideal for brackets and frames. BaoXuan utilizes high-powered fiber lasers for intricate drone profiles.
Waterjet Cutting: Ideal for thicker materials or heat-sensitive alloys where laser thermal effects are problematic, enabling cuts without altering material microstructure.
CNC Punching & Bending: Efficient for high-volume production of standardized parts. Modern CNC press brakes handle complex, multi-axis bends for enclosures, chassis elements, and mounting hardware with tight tolerances.
Prototyping & Low-Volume Solutions
For prototype development or specialized builds, BaoXuan leverages advanced turret punch presses combined with skilled manual finishing. This allows rapid iteration of antenna mounts, motor plates, and custom battery trays before committing to high-volume tooling.
Surface Treatments & Finishes
- Anodizing (Aluminum): Essential for corrosion resistance, electrical insulation on motor mounts, and aesthetic coloring.
- Passivation (Stainless Steel): Enhances corrosion resistance after machining.
- Powder Coating: Provides durable, customizable finish for structural components and shells.
- Chemical Film (Chromate Conversion): Offers electrical conductivity and corrosion protection for grounding or bonding surfaces.
BaoXuan applies aerospace-grade finishes ensuring long-term performance even in harsh operational environments.
Critical Quality Factors for Drones
- Precision Tolerances: Flight-critical parts demand tight geometric accuracy, often ±0.1mm or better, to ensure component alignment and balance.
- Rigorous Weight Management: Every gram impacts flight time and payload. Optimized designs and precise material removal are mandatory.
- Vibration & Fatigue Resistance: Parts must withstand continuous operational stresses without failure; material choice and process control are paramount.
Effective sheet metal fabrication requires integrating design for manufacturability (DFM) principles early, selecting appropriate alloys and processes for each component’s function, and maintaining stringent quality control throughout.
