Metalstar’s small-batch sheet metal processing (order quantity ranging from 10 to 500 pieces) is characterized by a wide variety and customization, serving as a crucial link between product development verification and mass production. The entire process is optimized around “flexibility, low cost, and fast response”. The core steps are as follows:
Firstly, design optimization and process pre-audit: After the customer provides the drawings, engineers complete DFM (Design for Manufacturability) analysis within 24 hours and adjust the plan according to the characteristics of small batches – for example, changing complex stamping structures to laser cutting molding to avoid mold cost; marking process parameters such as minimum bending radius and hole edge distance to avoid issues such as bending rebound and hole position deformation. This step can reduce the rework rate of trial production by 40%.
Second, flexible cutting and precise processing: Abandoning traditional mold-opening cutting, laser cutting or digital punching is adopted to complete cutting. The precision of laser cutting can reach ±0.1mm, adapting to the needs of irregular and multi-specification sheet metal parts. The cutting of a single product only takes 1-2 hours; in the forming process, a CNC bending machine is used, with the angle error controlled at ±0.5°. Coupled with rapid mold change tooling, the changeover time is compressed to within 30 minutes, perfectly adapting to the switching of orders with multiple varieties and small batches.
Thirdly, post-mold processing and comprehensive inspection: Welding employs flexible processes such as argon arc welding and spot welding, followed by grinding and polishing to ensure a smooth appearance. Surface treatment supports small-batch customization – electrostatic powder coating is cost-effective and has a short cycle (completed in 3 days), and liquid paint is suitable for large sheet metal parts that cannot be transported. The comprehensive inspection process verifies dimensions through 3D scanning and caliper measurement, with 100% visual sampling to ensure compliance with customer design standards.
Fourth, customized delivery: Provide protective packaging according to order requirements, develop shockproof foam for samples, and use waterproof film + cardboard boxes for bulk orders; support flexible requirements such as partial delivery and urgent additional orders, with regular orders delivered within 7-10 days and urgent samples shipped within 3 days, ensuring flexibility and quality stability throughout the entire process for small batches.
Metalstar looks forward to collaborating with you!