Case Studies — Precision Sheet Metal Success Stories
Detailed project case studies from proof of concept to production ramp across medical, aerospace, automotive, semiconductor, telecom and industrial automation
Why Case Studies Matter
In precision sheet metal manufacturing, detailed project case studies do more to build trust and accelerate buying decisions than generic claims. Each case shows the challenge, our approach, key processes and inspections, and measurable outcomes.
In-Depth Analysis
Full project narratives including DFM changes and validation
Downloadable Reports
FAI reports, CMM data, and inspection documentation
Easy Filtering
Sort by industry or project type for quick access
Measurable Results
Lead time, cost, yield, and quality metrics
Medical Surgical Instrument Housing
MedicalChallenge:
Biocompatible stainless steel housing with complex internal geometry, requiring ±0.05mm tolerances and FDA-compliant surface finish.
Solution:
Fiber laser cutting + precision CNC bending + electropolishing to Ra 0.4μm finish. Custom fixturing for consistent weld quality.
Result:
99.8% first-pass yield, 3-week lead time reduction, full FAI and MTR documentation provided.
Aircraft Avionics Bracket Assembly
AerospaceChallenge:
Lightweight aluminum bracket requiring AS9100 certification, complex multi-angle bends, and weight reduction of 30% vs. machined part.
Solution:
Optimized nesting pattern + multi-stage press brake forming + anodizing Type III. Custom tooling for compound angles.
Result:
35% weight reduction achieved, AS9100 compliance, 50% cost reduction vs. machined alternative.
EV Battery Pack Housing
AutomotiveChallenge:
Large format aluminum housing for EV battery pack, requiring IP67 sealing, crash safety compliance, and high-volume production capability.
Solution:
Automated fiber laser cutting + robotic MIG welding + leak testing station. Progressive die for high-volume stamping features.
Result:
100% leak test pass rate, 40% cycle time reduction, IATF 16949 compliance achieved.
Wafer Processing Chamber
SemiconductorChallenge:
Ultra-clean stainless steel chamber for semiconductor processing, requiring ±0.02mm tolerances and plasma-resistant surface finish.
Solution:
Precision laser cutting in cleanroom environment + orbital TIG welding + electropolishing to mirror finish. Class 10 cleanroom assembly.
Result:
Zero particle contamination, Ra 0.1μm surface finish achieved, 99.99% uptime in customer facility.
5G Base Station Enclosure
TelecomChallenge:
Weather-resistant aluminum enclosure for 5G equipment, requiring EMI shielding, thermal management, and outdoor durability.
Solution:
Integrated heat sink design + gasket grooves + powder coating with UV resistance. EMI testing and thermal simulation validation.
Result:
-40dB EMI shielding, IP65 rating achieved, 15°C temperature reduction vs. baseline design.
Robotic Arm Joint Housing
IndustrialChallenge:
High-strength steel housing for industrial robot joint, requiring fatigue resistance for 10 million cycles and precision bearing fits.
Solution:
Stress-optimized design + precision machining of bearing surfaces + heat treatment for fatigue resistance. FEA validation of stress concentrations.
Result:
20 million cycle fatigue life achieved, ±0.01mm bearing fit tolerance, 25% weight reduction vs. cast alternative.
How to Use This Page
Navigation & Filtering
- Use top filters to find cases by industry or project type
- Each case includes quick-scan summary for fast assessment
- Download buttons provide detailed technical reports
- Request quote for similar projects directly from case cards
What Engineers Should Look For
- Before vs. after tolerances and surface finish specs
- Fixturing, weld sequence, and inspection methods
- Material thickness and key features for cost estimation
- Quality documentation (FAI, CMM, MTR) availability
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