Custom sheet metal welding is to weld multiple sheet metal parts together to achieve the purpose of processing or single parts edge seam welding to increase its strength.

 

The custom sheet metal welding often uses oxygen arc welding, resistance spot welding, carbon dioxide gas shielded welding and manual arc welding. The specific welding process selection and scheme formulation need to be combined with the material, shape and use of sheet metal parts for specific consideration. When selecting the process of sheet metal fabrication welding, the technical requirements should be put in the first place, and the processing and manufacturing costs should be properly considered. In the actual welding sheet metal fabrication process, carbon dioxide gas shielded welding and argon arc welding are the most commonly used welding. Because the welding effect of sheet metal materials is limited by the welding equipment to a certain extent. For this reason, sheet metal parts should be selected with a thickness of less than two millimeters. The splicing process before welding should be prepared in advance for subsequent welding work. In the key parts of the welding machine tool, the plate needs to be fully aligned, and after ensuring that the surface is flat and there are no gaps, continuous spot welding is adopted. After the welding is completed, the seam is treated with sheet metal glue for waterproofing. If thicker materials are encountered and there are technical requirements such as full welding, the corresponding current and voltage need to be adjusted, and the welding sequence of the corresponding operation is adjusted by segmented full welding. For the welding of sheet metal parts for different purposes, there may also be certain processing technology and process differences. For example, for sheet metal parts that require high tightness such as fuel tanks. In order to avoid welding defects, it is necessary to use an open groove in the flat welding position to weld full. After the welding is completed, polish and smooth and timely oil leakage detection.

 

Sheet Metal Welding Process

 

1. Put the workpiece in the accurate position according to the requirements of the drawing, and then weld it after the measurement is qualified. If necessary, with the help of tire fixtures;

 

2. Try to use flat welding when welding, if welding in other positions, the welding current should be adjusted to reduce it by 10% than the flat welding current;

 

3. During the welding process, it is necessary to measure whether the size meets the requirements at any time to prevent the deformation;

 

4. When the weld is long or the structure is assembled, it should be fixed by spot welding in sections and then welded to avoid deformation;  

 

5. The arc pit should be filled when closing the arc, and the maximum arc pit should not exceed 5mm;

 

6. After welding ,knock out the chemical skin, clean the welding tumor and welding slag, and ensure that the weld seam is smooth and clean;

 

What Are The Advantages And Disadvantages Of Welding In Sheet Metal Fabrication Services

 

 

The advantages of Welding:

 

The welding process is a sheet metal fabrication process that is easy to mechanize and automate in processing.

 

Sheet metal welding simplify the processing and assembly, improve the sheet metal production efficiency.

 

Provide greater flexibility in structural design;High structural strength and good joint sealing;

 

Save a lot of metal materials, welded sheet metal parts reduce the weight of the component and increase the material usage to greatest extent, reduce product cost.

 

The tightness and waterproof performance of the welding of sheet metal parts have been significantly enhanced.

 

The Disadvantages of Welding:

 

High temperature, strong light and some toxic gases are produced in welding, which has certain damage to the human body, so it is necessary to strengthen labor protection.

 

The welded joint has a large performance inhomogeneity, due to the different composition and metallographic structure of the weld and the base metal, the thermal cycle experienced by each part of the joint is different, so that the performance of the joint in different areas is different;

 

The welding structure is easy to cause large residual deformation and welding internal stress. Since most welding methods use local heating, the welded parts after welding will inevitably stress and deformation in the structure, thereby affecting the bearing capacity, processing accuracy and dimensional stability of the structure. At the same time, it will also cause stress concentration at the junction of the weld and the weldment, affecting the brittle fracture of the structure;

 

There are a certain number of defects in welded joints: such as cracks, pores, slag inclusions, not welded through, not fused, etc. Defects can reduce strength, cause stress concentration, and damage weld compactness;

 

As one of the leading precision manufacturing companies in China, YS Rapid has been engaged in rapid prototyping and precision quality machining services with more than 10 years, helping many OEM customers in a wide ranges of industries to turn their ideas into markets and achieved good benefits.

 

 

 

Silicone rubber prototype  materials are commonly used many industries to create a wide variety of silicone & rubber parts, from aircraft parts,automotive, electronics,medical to small baby milk-bottle nozzles, etc. The materials used for rapid rubber prototyping are produced with variety of forms, compounds, and fabricating methods,which are generally narrow down to two types: Solid silicone rubber (including High-Consistency Rubber (HCR) & high temp vulcanizing (HTV) rubber) and Liquid Silicone Rubber (LSR).  Solid silicone rubber molded parts are mainly manufactured by silicone compression molding, while LSR molded parts manufactured by LSR injection molding.

 

As one of advanced rubber prototype manufacturers , YS Rapid strives to improve the quality of lsr prototyping to meet the needs of a wide variety of silicone and rubber parts in various industries.

 

Features of Silicone Rubber Prototyping

 

1. Silicone rubber parts are widely used in many products, such as silicone sealing ring, silicone ring, silicone gasket, silicone membrane, silicone plug, silicone O ring, and so on. The creation of silicone rubber prototype is tailored to meet various customer specifications, encompassing material type, hardness, color, electrical conductivity, and more.  

 

2. As a China rapid rubber prototyping  supplier and a reliable rubber prototype manufacturer, we offer customized rapid rubber prototyping services, including silicone compression molding and LSR injection molding, from mold design, mold manufacturing, silicone rubber parts prototyping and production, packaging and shipping, etc.

 

Introduction of Silicone Compression Molding & LSR Injection Molding And Their Processes

 

1. Silicone Compression Molding

What is Silicone Compression Molding?

 

Compression molding of silicone is the process in which putting solid silicone rubber with vulcanizing agents into the cavity of each half of the mold, and then assemble the mold, and put the mold into a high temperature compression molding press to form the parts in cycle time. The hardness of molded silicone part is usually 30 -70 Shore A. Silicone parts can be made in almost all color which can be match with the Pantone color card number. The shape of the mold determines the shape of the silicone product. The compression molded silicone product is currently the most widely used in the silicone industry such as silicone industrial accessories, gifts, bracelets, watches, key bags, mobile phone sets, kitchen utensils, mats, ice trays, cake molds, etc.

 

2. LSR Molding

What is LSR Molding?

 

Liquid Silicone Rubber (LSR) moulding, sometimes is also named as Liquid Injection Moulding (LIM), is the process in which the LSR feeder fully mixes the liquid raw material from two separate components (A+B) in a precise 1:1 ratio, and because some of the products are colored designs, they are equipped with a color pump and a color metering part. A+B components, additives, colors, etc. are fully mixed and then put into the plasticizing system. This plasticizing screw has the functions of homogenization and mixing. The mixture is injected into the hot mold through the screw. At the mold temperature of 170-200 °C, the silica gel undergoes a curing reaction and form the flexible silicone parts within seconds.

 

Silicone Rubber Prototyping Details and Options

 

Process of silicone compression molding

 

Firstly, Making compression mold

 

The mold making starts with mold design as per the part 3D, then programming, cnc machining the rough shape, and then EDM spark and engraving machining, finally surface finish such as polish, texture, etc as per customer’s requirement.

 

Secondly, according to the customer's requirement, feed the raw silicone through a the silicone mixing roller to mix in required colouring.

 

The commonly used materials for processing are: silica gel, nitrile rubber, ethylene propylene rubber, fluorine rubber, etc. The color matching process should be done carefully, which needs constant pulling, cutting, flipping, etc. to make the color fusion more uniform. After the finished product comes out, the color remains the same, and the pass rate is high!

 

Cutting the material

 

After the silicone rubber compound is mixed, it is placed for 24 hours , and then according to the requirements of placing the rubber strips in the production and forming operation instructions, the rubber cutting and preparation processing are carried out, and the cut rubber materials are weighed and placed on the shelf for use.

 

Compression molding

 

After cutting the mixed silicone rubber into strips, and it needs to be weighed in the molding department to avoid loss and waste, and then put into the mold for compression molding at a high temperature of 200 °C.

 

The molded silicone rubber parts usually have some flash, etc, it needs to use scissors and pliers to clean the flash.

 

IPQC inspection and packing

 

The quality staff inspect the molded rubber parts to check if meets requirement, such as appearance, size, function, etc. After IPQC, the products are packed and delivered to customers.

 

Advantages of silicone compression molding

 

Silicone compression molded parts are tensile, tear-resistant, shock-resistant, stable performance.

 

It resist low and high temperature (-30 degree C to +260 degree C)

 

It can be Waterproof, fireproof, dustproof;

 

The silicone compression molded parts are high precision, regular and beautiful shape.

 

It allows adjusting any color matching the in

 

The Process of LSR Molding

 

The molding machine for LSR---Liquid Injection molding machine, Short name LIM machine

 

LIM uses a quantitative device (feeder) to control the ratio of two materials (component A and component B) at a ratio of 1:1. If the product has color requirements, add color paste (or additives, etc.), and then pass the mixer to fully After the mixing is pumped into the barrel of the injection molding machine, the screw accurately injects the liquid silicone into the mold cavity. At a certain mold temperature, the liquid silica gel undergoes a curing reaction.

 

Following are the major steps used in the LSR molding process:

 

Uncured liquid silicone containing two containers, Compound A and Compound B, connected to the pump system. Drum contains the base forming material and Drum B contains the catalyst. A metering device automatically releases the two substances and the pigment additive in a fixed 1:1 ratio.

 

LIM machine can program and customize the automatic molding machine and make injection settings to provide the correct injection volume for each job. Align the platen and piston to close the mold, and set the temperature, pressure, firing rate and cycle time according to customer requirements.

 

After the shaping is completed, the molding machine will heat the mold to a suitable temperature and apply a suitable clamping force. The mold is closed together with the machine's syringes, pumps and supplies. The injection mechanism then pushes the material into the mold and cavity.

 

Apply heat and pressure to the liquid silicone rubber to cure the material. After the cycle is complete, the mold is opened and the part and burrs are removed automatically or by an operator. Then close the mold and repeat the process.

 

After the product is released from the mold, it will perform post-molding processes such as deburring, secondary curing, inspection, and packaging.

 

Advantages of LSR Injection molding

 

Non-toxic, can be used for medical and food use.

 

Non-toxic to human body, odorless and tasteless. LSR is more used in little baby’s products

 

Environment friendly, it is degradable;

 

No toxic and harmful substances are produced during combustion (the combustion products are mainly SiO2);

 

Tear strength, resilience, water resistance and waterproofing;

 

Weather resistance: Due to the high Si-O bond energy, higher energy than ultraviolet radiation, it is not easy to be decomposed by ultraviolet light and ozone, so it has good ultraviolet resistance, ozone resistance and aging resistance;

 

Temperature resistance: good heat resistance and cold resistance, long-term use in the temperature range of -50℃~200℃, it still has good elasticity, no melting and embrittlement (special products can reach -110℃);

 

Excellent Electrical insulation performance: its dielectric loss, withstand voltage, arc resistance, corona resistance, resistivity, etc. are among the best in insulating materials, and electrical properties are rarely  affected by temperature and frequency;

 

Biological compatibility: Polysiloxanes are among the most inactive compounds known. They are very resistant to biological aging, have no rejection reaction with animals, and have good anticoagulant properties.

 

Fast turn-around: LSR has low viscosity, fast vulcanization, shear thinning and high thermal expansion coefficient before curing, and can be produced by injection molding, rapid and repeatable mass production.

 

As one of the leading precision machining suppliers in China, YS Rapid has been engaged in rapid prototyping and high precision china machining services with more than 10 years, helping many OEM customers in a wide ranges of industries to turn their ideas into markets and achieved good benefits.

 

 

Precision Sheet Metal Stamping is also called Sheet Metal Punching or Sheet Metal Pressing, is a process to obtain stamped parts of the desired shape and size through the use of the force of presses and stamping molds to deforming or separate the parts from the metal plates, strips, tubes,etc. Generally, the processing of china custom sheet metal stamping has stamping corner, stamping blanking, stamping convex hull, stamping tearing, hole extraction and other processing methods to achieve the purpose of processing. Its processing needs to have a corresponding stamping mold to complete the operation. There are convex molds for stamping and tearing, tearing forming dies for punching and tearing, etc.

 

The main blanks for metal plate stamping are hot-rolled or cold-rolled steel plates or strips. In the world, 60-70% of steel is plate, most of which will be stamped into finished products.

 

How Does Sheet Metal Stamping Work?

 

Sheet Metal stamping is the use of punching machines and stamping mold to process stainless steel, Iron, Aluminium, Copper, etc to deform or break to obtain a certain shape and specification. Sheet Metal stamping processing is simple to operate, production is efficient, and it is convenient to complete mechanization.

 

Let's take a closer look at the process of sheet metal stamping:

 

1. Material preparation: The materials required for the mold vary from product to product. It is necessary to choose the appropriate mold material according to the characteristics of the product, such as: mold. Top cover and upper splint. Stripping plates. Lower mold. Pad block. Bottom plate, etc.

 

2. Primary processing: After material selection, first use a milling machine to process the plane and side. Common methods are to apply wood-based panels, stripping machines, lower templates, pads, bottom plates, top covers, and top plates.

 

3. Precise processing: flat and four corners at bevels must be machined and processed. Stripping plates. The lower template is beveled to the bottom plate, and the bottom plate is smoothed with the upper cover.

 

4. Line drawing: Put the template finished into an oblique angle at the drawing line. According to the mold drawing drawing, draw the line with a line height ruler, and finally draw the points on the die head after the line and Tapping teeth.

 

5. Plate: In order to ensure the strength of plate, it is quenched at high temperature. Quench. Tempering. After annealing and other processes, further finishing, the plate is crushed into an oblique angle, and then the wire is broken.

 

6. Install the mold trial: select the mold base or support guide column. The guide column completes the mold assembly, installs the installation mold in the stamping machine for adjustment, and finally carries out mold inspection on the stamping precision hardware to determine whether it meets the commodity regulations and completes the whole process of fitting.

 

Advantages of Sheet Metal Stamping Services

 

Low cost

 

Sheet metal stamping is a low-cost precision quality machining technology. Its cost is much lower cost than other processing to mass produce hundreds of thousands of parts. Stamping products do not need or only need a small amount of custom machining, the material utilization rate is high, and the material cost of the workpiece is low.

 

High quality.

 

Sheet metal stamping produce parts in good quality, such as smooth surface, high precision, dimensional stability, and good interchangeability; Light weight, good rigidity, high strength; The stamping process can also process workpieces that are difficult to machine by other processing methods, such as thin-shell parts, workpieces with flanges, undulations, stiffeners, etc. The strength and stiffness of the stamped parts are also very high, which is due to the cold deformation and hardening of the material during the stamping process.

 

High volume production

 

sheet metal stamping can produce thousands of the same parts quickly. This type of custom sheet fabrication allows you to maintain inspection standards and manufacture many goods efficiently. The structure of the mold used in stamping processing is generally more complex, the mold production cycle is long and the cost is high. Therefore, the sheet metal stamping process is mostly used for high volume production.

 

Easy operation:

 

cutting machines, stamping machines and bending machine molds make up the vast majority of tools for stamping metal plates, so relative manufacturing process is very easy to learn and train. If you have employees who already know how basic equipment actually works, they may understand how to stamp sheet metal quickly.

 

Wide Application

 

Sheet metal stamping is a very widely used manufacturing technique that can build parts of various shapes and sizes. It is an excellent choice for companies that need to mass produce the parts. Stamped parts have a wide range of sizes, and the shape of stamped parts can also be complex. Stamped parts are widely applied in many industries, from small pieces such as stopwatches to large pieces such as car stringers and coverings.

 

Why choose us as your Chinese sheet metal stamping manufacturer, sheet metal stamping supplier, sheet metal stamping factory?

 

Combined manufacturing services, provide all our rapid prototyping needs

 

Our mold tools can manufacture hundreds of thousands of stamped parts rapidly

 

Excellent accuracy Sheet metal processing

 

Hundreds of stamping materials include aluminum, zinc and magnesium,stainless,copper,brass so on

 

Multiple Surface finishes available for your metal stamped parts

 

As one of sheet metal stamping factories, we will do our best to meet all the needs of customers.

 

At YS Rapid, we provide excellent quality rapid prototyping, cnc machining and low volume manufacturing services to support your different project development needs. Our professional engineering team and precision machining company with advanced equipment can support you optimize the design, and transform your designs and ideas into great products within a few days through suitable manufacturing process, such as cnc machining, vacuum casting, sheet metal fabrication, silicone molding, pressure die casting, injection molding and surface finishing services.

 

If you want to know more about precision machining china services, please visit our website.

 

 

Are you looking for a custom sheet metal fabrication supplier in China? YS Rapid is a good choice to you, not limited to quantity, from sheet metal prototyping to volume production. We are one of the leading china sheet metal fabrication companies and china sheet metal fabrication manufacturers, providing one stop solution of custom sheet fabrication including sheet metal cutting, sheet metal bending, sheet metal stamping, sheet metal folding, sheet metal welding, assembly, etc. YS Rapid's china sheet metal fabrication services have been serving for variety of industries, such as medical equipment, telecommunication devices, electrical equipment, mechanical equipment, and so on.

 

What is Sheet Metal Fabrication?

 

Sheet metal fabrication is manufacturing process of shaping flat sheets of steel or aluminium into required structures & dimensions of the products. The main sheet metal fabrication process include cutting, punching, folding, riveting, and assembling, and so on. Sheet metal parts are thin-plate metal parts, generally, the thickness sheet metal part is constant and not changed during the processing. Many products in our daily life are manufactured by custom sheet fabrication, such as Chassis shell, machine's shell, distribution box, control cabinet, network cabinet, chimneys, iron drums, fuel tanks and oil cans, ventilation pipes, Stainless steel cup, stainless steel box, and so on.

 

Custom Precision Sheet Metal Fabrication Services Types

Sheet Metal Cutting

YS Rapid provides high quality sheet metal cutting services. Our china sheet metal fabrication services support a wide variety of metal materials including steel, stainless steel, aluminum, brass, bronze, copper and more.

 

Sheet Metal Bending

We work with all different industries to provide high quality on-demand sheet metal bending services in steel, stainless steel, aluminum, brass, bronze, copper and so on.

 

Sheet Metal Stamping

We provide custom sheet metal stamping service to clients in all industries and produce sheet metal prototypes and short to medium run sheet metal stamping parts to meet all customer design specifications.

 

Sheet Metal Welding

We provide customers with professional, high-quality, consistent, and reliable sheet metal welding services.

 

How Does Custom Precision Sheet Metal Fabrication Works?

Sheet metal fabrication is an industry term. To understand it simply, it is to process different sheet metal materials into desired shape & surface finish sheet metal parts.

 

High-precision sheet metal processing tolerance range: bending: -+/-0.1mm, CNC machining: -+/-0.1mm, laser cutting -+/-0.1mm

 

Following are Common processes of Sheet Metal Fabrication:

 

Sheet Metal Cutting

 

Generally, the first step of sheet metal fabrication is cutting, in this process, flat metal plate is cut to the required size and shape by cutting tools. There are several ways of cutting, includes laser cutting, shearing, punching, etc. Among them,Laser cutting is one of the most common cutting methods in sheet metal processing. The metal stainless steel and other plates are laser cut into the required size according to the specifications for later use. This process is also called blanking.

 

Sheet metal bending

 

The second step of sheet metal fabrication is precision sheet metal bending, which means bending the metal sheet which has been cut into required shape. It needs to notice that bending parts have a minimum bending radius. When the material is bent, the outer layer is stretched and the inner layer is compressed on the fillet area. When the thickness of the material is constant, the smaller the inner bending radius, the more severe the stretching and compression of the material; when the stretching force of the outer layer exceeds the limit of the material, fracture and snapping will occur.

 

Sheet metal welding and assembly

 

Assemble the metal plates into a complete products. The assembly process may includes welding, riveting, brazing, etc.

 

For welding, there are mainly ways: arc welding and gas welding.

 

Arc welding: it has the advantages of flexibility, maneuverability, wide applicability, and all-position welding; the equipment used is simple, durable, and low maintenance costs. However, the labor intensity is high and the quality is not stable enough, depending on the level of the operator. It is suitable for welding carbon steel, low alloy steel and copper, aluminum and other non-ferrous alloys with a thickness of more than 3mm.

 

Gas welding: The temperature and properties of the gas welding flame can be adjusted. Compared with arc welding, the heat source is wider than the heat-affected zone, the heat is not as concentrated as the arc, and the productivity is low. It is applied to the welding of thin-walled structures and small pieces, and can weld steel, cast iron, aluminum, copper and other materials. alloy, hard alloy, etc.

 

Finally, the last step of sheet metal fabrication is surface finish. If the assembly has welding, riveting, the parts must be polish and clean and must have a good surface treatment. Common surface finishes for sheet metal fabrication services are as follows:

 

Polishing

 

Pre-polishing is the process of using a hard polishing wheel to treat the surface of the polished stainless steel sheet metal parts, which can remove the rough marks on the grinding surface. Fine polishing uses a soft surface to further process the pre-polished surface, remove the traces left by the pre-polishing, and obtain a bright mirror surface.

 

Mercerized

 

The mercerizing effect is the process of using the brushing wheel installed on the polishing machine to process the surface of the stainless steel sheet metal parts to obtain decorative silk brushing and satin finishing effects.

 

Sandblasting

 

Sand blasting effect, using compressed air flow to spray sand or steel shot, glass shot and other abrasives on the surface of stainless steel sheet metal part to make it appear uniform and beautiful, slightly rough sandy surface.

 

Baking paint

 

By spraying, high-temperature baking, etc., a layer of paint of various colors is sprayed on the surface of the sheet metal material to beautify the appearance and increase the anti-corrosion performance of the material (Generally there are two kinds of liquid baking varnish and powder baking varnish).

 

Electroplating

 

Through chemical reaction, it is a commonly used surface treatment method to attach a layer of other metals on the surface of sheet metal parts to increase the anti-corrosion performance of the metal and achieve a certain beautification effect, such as electro-galvanizing and electro-nickel plating.

 

Anodizing

 

Oxidize the metal on the surface of sheet metal parts to form a dense protective film on the surface of the workpiece to increase the corrosion resistance of the workpiece. Generally, there are two methods: chemical oxidation and anodic oxidation.

 

What Are the Materials Usually Used for Custom Precision Sheet Metal Fabrication Services?

Different products has different requirement. It needs to combine with the function, cost to select the suitable material for sheet metal parts. The commonly materials used for sheet metal fabrication are cold-rolled sheet (SPCC), hot-rolled sheet (SHCC), galvanized sheet (SECC, SGCC), copper (CU) brass, red copper, beryllium copper, aluminum sheet (6061, 5052, 1010, 1060, 6063, hard aluminum, etc.), stainless steel (mirror surface, brushed surface, matte surface) and so on.

 

Why Choose Our Custom Precision Sheet Metal Fabrication Services?

 

Fast Machining Speed

 

One significant advantage of our sheet metal fabrication is that the cutting speed is fast, and it is not limited by the number of processing. It is cost-effective for the processing of special-shaped workpiece because it does need to waste time to replace the cutting tool and thus effectively improves the processing speed; To some extent, its processing speed and the maximum positioning speed are significantly faster than wire cutting.

 

High efficiency & quality

 

As a Chinese precision quality machining manufacturer, we provide cheap sheet metal laser cutting services. Laser cutting belongs to non-contact cutting, and its cutting edge is less affected by heat, which can avoid the thermal deformation of the workpiece. And it can avoid the slump when the plate is cut, and the cutting seam generally does not require secondary processing, which improves the work efficiency; In addition, its cutting head will not contact with the material surface, ensuring the metal sheeet not scratched.

 

Wide range of materials for processing

 

Our Sheet metal fabrication service can quickly process aluminum plates and hard metal plates without deformation, regardless of the high hardness. Besides, we can not only can process any kinds of graphics but also can cut pipes and other strange shape materials, and we can also cut most non-metallic materials quickly, so it is not limited by material properties.

 

At YS Rapid, we provide excellent quality rapid prototyping, cnc machining and low volume manufacturing services to support your different project development needs. Our professional engineering team and china precision machining factory with advanced equipment can support you optimize the design, and transform your designs and ideas into great products within a few days through suitable manufacturing process, such as cnc machining, vacuum casting, sheet metal fabrication, silicone molding, pressure die casting, injection molding and surface finishing services.