Manufacturing process of metal shell
Nov 05, 2025
The entire process of making metal shells
🎯 Phase 1: Design and Modeling
✏️ Requirement analysis and conceptualization
Clearly define requirements for functionality, protection level (IP), heat dissipation, structural strength, etc.
🎨 industrial design
Use software such as Rhino and Alias for appearance, surface, and texture design.
📐 structural design
Use CAD software such as SolidWorks and UG to design internal structures, wall thickness, reinforcement bars, screw columns, etc.
🔬 simulation analysis
Perform stress and thermodynamic simulations using CAE software to optimize design.
🧩 Prototype production
Use 3D printing or CNC prototyping to create physical prototypes for verification.
⚙️ Phase 2: Process selection and mold making
📋 Core process selection
Die casting - suitable for complex shapes and large quantities.
CNC machining - suitable for high precision and small batch production.
Stamping - suitable for sheet metal and large quantities.
🔨 mold making
Design ->Material Selection (Mold Steel) ->Precision Machining (CNC/EDM) ->Polishing and Debugging
🏭 Phase Three: Main Forming and Processing
Path 1: CNC machining
📌 Cutting -> ⚒️ Rough machining -> 🔎 Precision machining -> 🕳️ Drilling/Tapping -> ✅ deburring
Path 2: Die casting
🔥 Melting -> 💨 Injection -> ❄️ Cooling → 📤 Mold opening and ejection -> ✂️ degating
🎨 Stage Four: Surface Treatment
🧽 preprocessing
Polishing/sandblasting, cleaning, chemical conversion.
✨ Core surface treatment process
Anodizing - preferred for aluminum materials, wear-resistant and colorable.
Electroplating - chrome plating, nickel plating, etc., used for corrosion prevention or conductivity.
Spray painting or powder coating provides color and protection.
Drawing - Creating metallic textures to enhance aesthetics.
🔎 Stage 5: Quality Inspection and Assembly
📏 quality inspection
Dimensional inspection (CMM), appearance inspection, performance testing (salt spray test).
🔧 Assembly and packaging
Pre embedded fasteners ->Assembly assembly ->Labeling ->Scratch resistant packaging -> 🚀 shipment
