Custom Sheet Metal Mounting Brackets (Low Volume Manufacturing Case)
At KAIAO, we specialize in transforming flat sheet metal into precise, functional components. This case study highlights our capability in producing custom multi-bend mounting brackets for structural applications, demonstrating our expertise in strict tolerance control and surface finishing.
Project Specifications
Part Name: Custom Sheet Metal Mounting Bracket / Fastening Connector
Material: Aluminum Alloy (AL5052 / AL6061) or customized to your requirements.
Thickness: 1.5mm - 2.0mm (Customizable)
Manufacturing Processes: Laser Cutting, CNC Bending, Tapping, and Deburring.
Surface Treatment: Clear Anodizing / Sandblasting (Ensures corrosion resistance and a smooth, cosmetic appearance).
Manufacturing Challenges & KAIAO's SolutionsFor brackets featuring multiple bends and mounting holes (as shown in the gallery), maintaining dimensional stability is the primary challenge.
Precision Bending: When executing 90-degree bends on this specific part, springback can affect the final assembly tolerance. Our engineers calculated the exact bend deduction and utilized precision CNC press brakes to guarantee the angle tolerance is controlled within +/- 0.5°.
Hole Alignment: The mounting holes were laser-cut prior to bending. To prevent hole deformation during the folding process, we optimized the flat pattern design and maintained a safe minimum bend radius.
Smooth Edges: After the laser cutting and punching processes, the parts inevitably have burrs. We applied professional sanding and deburring to ensure all edges are smooth and safe for final assembly without scratching mating components.
Why Choose KAIAO for Your Sheet Metal Parts?Whether you need 10 pieces for rapid prototyping verification or 10,000 pieces for low-volume production, KAIAO provides a seamless manufacturing experience. We eliminate tooling costs for simple bent parts and offer rapid lead times compared to traditional CNC machining.
Looking for similar custom sheet metal parts?Upload your 3D CAD files today, and our engineering team will provide a DFM (Design for Manufacturing) review and a competitive quote within 24 hours.
One of the most important processes of rapid-sheet-metal is the bending, this is a key for the dimension stable and commitment to the tolerances, normally we will bend inner shape then outer shape, to bend the small shape then bigger shape, and to bend special shape then to the simple shape, if there is bending shape that need to bend to the bend, normally to bend to about 30~40°, then use flat mold to press it to the end.
After all these processes are finished, the parts will go to do the post finishing if required. Different rapid sheet metal material will do different finishing, for example, aluminum sheet metal can do anodized, painting, plating, powder coat, while for steel and zinc plating sheet metal material, the finishing will be painting, plating, powder coat but not anodized.
No matte you are looking for sheet metal parts in quantity one piece or large amount quantities, KAIAO is able to provide you parts quickly and cheaply, just print the Request a Quote, we can talk now.
