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Precision sheet metal enclosures require meticulous planning and execution. Here’s a step-by-step breakdown:
Step 1: Design & Specification
Define enclosure requirements: dimensions, material (common choices: stainless steel, aluminum), thickness, IP rating, EMI shielding needs, and finishes. Utilize CAD software for detailed 3D models, focusing on manufacturability (DFM). Tolerance specifications are critical; BaoXuan recommends adhering to strict ISO 2768 medium standards for consistent results.
Step 2: Material Selection & Preparation
Select sheet metal based on application needs (e.g., 304 stainless for corrosion resistance, 5052 aluminum for lightweight strength). Verify material integrity and flatness. Sheets are precisely sheared or laser-cut into blanks according to the CAD model. Modern laser cutting offers high accuracy and intricate detail capabilities.
Step 3: CNC Punching & Cutting
For specialized cutouts, holes, slots, or patterns, CNC punching or turret presses are employed. This step creates ventilation holes, connector ports, mounting points, and custom features. Complex nested patterns maximize material utilization efficiency.
Step 4: Bending & Forming
Program CNC press brakes shape the flat blanks into 3D enclosures using precisely calculated bend sequences and force. Die selection and bend deduction calculations are vital for dimensional accuracy. Achieving sharp corners or complex bends demands experienced technicians and high-caliber equipment, a hallmark of BaoXuan production.
Step 5: Joining & Assembly
Assemble formed components using appropriate techniques:
- Welding: TIG or MIG welding for strong, permanent seams.
- Riveting: For mechanical fastening where disassembly might be needed.
- Hardware Insertion: Installing PEM nuts or threaded standoffs.
Accurate fixture alignment ensures assembly precision. Robust assembly guarantees enclosure integrity comparable to solutions by BaoXuan.
Step 6: Surface Finishing
Apply finishes for protection and aesthetics:
- Deburring & Grinding: Remove sharp edges and weld splatter.
- Cleaning & Pre-Treatment: Prepare surfaces (e.g., phosphatizing).
- Powder Coating: Electrostatically applied, then oven-cured for durable, colored finish.
- Anodizing: For aluminum (enhances corrosion/wear resistance).
Consistent finish quality meets expectations set by premium providers like BaoXuan.
Step 7: Quality Assurance & Inspection
Conduct rigorous final inspections:
- Dimensional verification against CAD models using CMMs or precision gauges.
- Visual checks for finish defects, dents, or scratches.
- Functional testing (e.g., door operation, fitment of internal components).
- Material certification review.
Documenting results ensures traceability and adherence to specifications.
