I. Manufacturing Process
This aluminum alloy shell has a cubic cavity structure with precision slots, holes, and assembly interfaces on the side walls. The manufacturing process primarily uses profile/sheet metal processing, supplemented by die casting. The core flow is as follows:
1. Raw Material Selection: 6063 aluminum alloy profiles are preferred (suitable for cavity stretching/extrusion forming, with good anodizing effect) or 6061 aluminum alloy sheets (high structural strength, suitable for complex milling). For mass production, ADC12 die-cast aluminum can be used as the blank.
2. Blank Forming:
◦ Profile Machining: The basic square tube cavity is formed by extruding aluminum profiles, then sawn to obtain a fixed-length blank, reducing subsequent milling allowance.
◦ Sheet Metal Machining: Sheet metal blanks are obtained using laser cutting/waterjet cutting, and then bent to form the cavity frame (suitable for non-standard small batches).
◦ Die Casting: For standardized mass production, blanks are cast using die casting, requiring only precision machining of key surfaces.
3. CNC Precision Machining: Utilizing a 4-axis/5-axis CNC machining center, the machine performs internal slot milling, hole drilling and tapping, surface finishing, and chamfering/deburring. Tooling fixtures (such as vises and positioning blocks) ensure coaxiality and perpendicularity during multi-faceted machining.
4. Surface Treatment:
◦ Hard Anodizing: The outer shell has a matte/semi-matte black finish, achieved through hard anodizing (5~20μm thickness), enhancing wear and corrosion resistance while maintaining a black color scheme. Some areas can be sandblasted and anodized for enhanced texture.
◦ Powder Coating/Baking: For outdoor use, electrostatic powder coating (polyester powder) is used for improved weather resistance. Matte/high-gloss black finishes are available upon request.
◦ Passivation/Brushing: Non-exterior surfaces undergo passivation for rust prevention, while brushing is applied to select exterior surfaces to enhance visual depth.
5. Post-processing and Inspection: After cleaning and degreasing, dimensions are checked using a 2D/3D coordinate measuring machine. Assembly trial fitting and appearance defect inspection (such as oxide layer uniformity and scratches) are performed.
II. Machining Accuracy
This housing is a precision electronic device cavity. Accuracy must match the assembly requirements of internal components and external interfaces. Key indicators are as follows:
1. Dimensional Accuracy:
◦ Key assembly positions (slots, screw holes, positioning pins): Tolerance controlled within ±0.03~±0.05mm.
◦ External contour (length/width/height): Tolerance ±0.1mm, ensuring compatibility with equipment assembly.
◦ Hole position accuracy/coaxiality: ≤0.08mm, ensuring smooth wiring and connector assembly.
2. Geometric Tolerances:
◦ Flatness: Mounting surface/mating surface ≤0.05mm/100mm, avoiding assembly gaps.
◦ Verticality: The gap between the cavity sidewall and bottom surface is ≤0.05mm to ensure the installation accuracy of the internal circuit boards/modules.
◦ Parallelism: The parallelism between corresponding slots/holes is ≤0.06mm to prevent component jamming.
3. Surface Precision:
◦ Surface roughness Ra1.6~3.2μm (after anodizing), non-surface surfaces Ra6.3μm is sufficient.
◦ Chamfer/corner radius tolerance ≤0.1mm to ensure consistent feel and appearance.
III. Industry Applications
This type of cubic aluminum alloy cavity shell, due to its lightweight, electromagnetic shielding (aluminum material can shield electromagnetic interference), and high structural rigidity, is widely used in smart hardware, industrial control, security equipment, and other fields:
1. Smart Hardware Field:
◦ Smart home central control module shell, IoT gateway shell, smart sensor (temperature, humidity/infrared) cavity.
◦ Small smart robot core module shell, drone flight control system cavity.
2. Industrial Control:
◦ Industrial PLC module housings, servo driver housings, and small industrial computer housings, utilizing the heat dissipation and anti-interference properties of aluminum alloy to protect core circuits.
◦ Signal adapter boxes and wiring housings for automation equipment, adapted to the corrosion resistance requirements of industrial environments.
3. Security Equipment:
◦ Housings for small surveillance camera modules, internal modules of building intercom units, and access control controllers.
◦ Main unit housings for portable security detectors, with a lightweight design for easy field use.
4. Consumer Electronics:
◦ Housings for portable projectors, metal housings for Bluetooth speakers, and small game console main units, balancing aesthetics and structural protection.
5. New Energy:
◦ Housings for control modules of small energy storage power supplies and signal acquisition modules for charging piles, utilizing the heat dissipation properties of aluminum alloy to meet the needs of power equipment.
