| Client | A leading consumer electronics brand |
| Sector | Consumer Electronics |
| Region | China, supplying domestic and export markets |
| Programme | Consumer electronics aluminium housing profiles |
Client identity is described by market position rather than by name, in line with our confidentiality commitments.
Extruded aluminium housing profiles for a leading consumer electronics brand, where the enclosure is both a visible retail surface and a part that has to feed automated assembly.
The challenge
Consumer electronics enclosures carry a contradiction: the surface has to look premium on a shelf, and the part has to be dimensionally predictable enough to run through an automated line without jamming. Both matter at the same time, and at consumer volumes neither can be solved by hand-sorting.
What we did
Polish-free 6063 to remove a whole finishing operation
Primary billet gives a surface fine enough to go straight to 180# blasting and anodising with no polishing stage — typically around 15% less finishing cost. At consumer volumes, removing an operation is worth more than shaving a percentage off the piece price.
±0.005 mm cut-to-length for line feed
Housings arrived at length and dropped straight into the fixture. Most customers find they can remove an in-house sizing step entirely, which is often the larger saving.
Short tooling cycle for a fast product cycle
New die in 4–5 days and samples in 7 days, with three rounds of free sampling, so enclosure geometry could be committed later in the design process rather than frozen early.
Capacity for a launch ramp
Roughly 3,500 tonnes of profile and 500,000 enclosures a year, with the option to hold extruded stock at our 3,000 m² warehouse and release machined batches on call.
Results
| Result | Measured |
|---|---|
| ~15% | Finishing cost removed via the polish-free route |
| ±0.005 mm | Cut-to-length accuracy for line feed |
| 7 days | From tooling to first samples |
- Housing profiles supplied for a consumer product range with visible-surface requirements.
- Finishing cost reduced by removing the polishing stage from the process route.
- Parts delivered cut-to-length for direct automated assembly.
- Tooling and sampling cycle short enough to fit an active product schedule.
Why it held in production
Every stage of this programme ran inside our own plant — tooling design, extrusion, CNC machining, surface treatment and assembly. That is the reason the result repeated rather than appearing once on a first article: when a parameter needs adjusting, we change it and verify it the same day instead of negotiating through a subcontractor. We hold ISO 9001 across the process, with wall thickness at ±0.02 mm against a GB standard of ±0.05 mm and cut-to-length at ±0.005 mm.
Other programmes
Have a similar enclosure programme? Send your drawing and we will review it free of charge.