At KAIAO, we specialize in rapid sheet metal prototyping and low-volume fabrication tailored to specific engineering needs. This case study highlights our manufacturing capabilities through the production of a custom Sheet Metal Mounting Plate, featuring precise elongated slots and controlled step bends.
This type of component is frequently used in industrial enclosures, server racks, and automotive assemblies where adjustable mounting and ventilation are required.
Part Name: Custom Slotted Mounting Plate / Adjustable Bracket
Typical Materials: Stainless Steel (SS304 / SS316), Aluminum (AL5052), or Galvanized Steel (SGCC) depending on customer requirements.
Thickness: 1.0mm - 2.5mm
Core Processes: CNC Laser Cutting, CNC Turret Punching, and Precision Bending.
Surface Finish: Brushed Finish, Deburring, or Custom Powder Coating.
Manufacturing flat plates with multiple cutouts and bends requires strict dimensional control to prevent material warping. Here is how the KAIAO engineering team ensures precision:
1. Precision Laser Cutting & PunchingThe primary features of this plate are the parallel elongated slots and circular mounting holes. To ensure absolute accuracy and clean edges, we utilize high-power CNC laser cutting. For larger production runs, CNC turret punching is applied to rapidly stamp the slot patterns, significantly reducing the unit cost and lead time.
2. Controlled Step BendingAs seen in the images, this plate features slight offset bends (step bends) near the ends. Bending a plate that has already been perforated with large slots can lead to material distortion or cracking near the holes. Our technicians calculate the exact bend deduction and use specialized press brake tooling to ensure the main flat surface remains perfectly straight without compromising the structural integrity of the slotted areas.
3. Edge Deburring and SafetyAfter cutting and punching, sheet metal naturally develops sharp burrs. Since mounting plates often involve manual assembly or wire routing, we apply professional mechanical deburring and edge rounding. This guarantees that the final part is safe to handle and cosmetically flawless.
Whether you need a single prototype for design verification or a low-volume run of 10,000 pieces, KAIAO delivers fast, cost-effective, and highly accurate sheet metal parts. We eliminate the need for expensive progressive dies for your early-stage production.
Upload your 2D drawings or 3D CAD files today, and our engineering team will provide a comprehensive Design for Manufacturing (DFM) review and a quote within 24 hours.
