Sheet Metal Fabrication Case Files
Written the way we would brief a colleague: what the part had to do, what the first drawing asked for, and what we changed. No customer names, and no invented savings figures — the engineering is the interesting part.
These are anonymised production cases — customer identity withheld under NDA, which is standard for contract manufacturing. Each file gives the part, the material and thickness, the constraint that shaped the design, the DFM changes we proposed, and how the job was inspected before it shipped.
Telecom Outdoor Enclosure A 1.5 mm SGCC Case File
An anonymised case file: an IP-rated telecom cabinet in 1.5 mm zinc-coated steel, from gasket-groove DFM to weld sequence, powder coat and flat-pack shipping.
Data Centre PDU Enclosure 1U Housing Case File
An anonymised case file: a 1U rack PDU housing in 1.2 mm cold-rolled steel, where busbar clearance, vent area and rack-fit tolerances set every dimension.
Automotive Stamped Bracket Laser to Progressive Die
An anonymised case file: a high-volume mounting bracket moved from laser cut and bent to a progressive die, and the strip layout that made the tooling pay.
BESS Cabinet Fabrication Frame, Doors and Fire Path
An anonymised case file: a battery energy storage cabinet where the welded frame carries the load, the doors carry the gasket and the vents drive the layout.
Industrial Control Cabinet Cut-outs & Glands
An anonymised case file: a machine control cabinet where the cut-out schedule, gland plate and drilling order decided whether the panel fitted first time.
EV Charger Enclosure Sealing, Earthing and Finish
An anonymised case file: a wall-mounted AC charger housing, where a continuous seal path, an unpainted earth stud and an outdoor powder coat decided the design.
Consumer Electronics Chassis A 0.8 mm SPCC Case File
An anonymised case file: a slim consumer electronics chassis in 0.8 mm cold-rolled steel, from cosmetic-zone DFM and embossing to flatness control.
Laser-Cut Chassis Assembly One Route to Finish
An anonymised case file: a welded chassis taken from flat sheet through laser cutting, forming, jig welding, dressing and finish under a single order.
Medical Device Enclosure A Stainless Case File
An anonymised case file: a stainless medical instrument housing — hygienic geometry, weld dressing, passivation and the documentation trail it needs.
Solar Inverter Enclosure Aluminium Case File
An anonymised case file: an outdoor solar inverter housing in aluminium — IP sealing, thermal management, salt-spray finish and gasket-groove DFM.
Power Distribution Cabinet A SGCC Case File
An anonymised case file: a floor-standing power distribution cabinet in zinc-coated steel — frame stiffness, busbar clearance, door alignment, earthing.
Server Rack Chassis A 19-Inch 2U Case File
An anonymised case file: a 19-inch 2U server chassis in cold-rolled steel — rack ear flatness, slide clearances, EMC gasket lands and airflow paths.
Robotics Mounting Plate Machined-Flat Case File
An anonymised case file: a robot cell mounting plate — datum strategy, flatness after welding, hole-pattern position and the fixture that held it.
CNC Machine Guarding Laser-Cut Panel Case File
An anonymised case file: interlocked machine guarding panels — mesh apertures, safe sight lines, hinged frames and a finish that survives coolant.
Copper Busbar Bracket Bend and Plating Case File
An anonymised case file: a copper busbar bracket — forming without cracking, bend-radius limits for C110, tin plating and contact-surface masking.
LED Luminaire Housing Anodised Case File
An anonymised case file: an LED luminaire housing in aluminium — thermal contact faces, anodising, masking for the LED board and outdoor sealing.
ATM Kiosk Panel Cosmetically Critical Case File
An anonymised case file: a banking kiosk face panel in SECC steel — appearance-class inspection, sub-panel tolerances and where silk-screening fits.
Fibre Splice Enclosure A Sealed Case File
An anonymised case file: an outdoor fibre splice closure — gasket compression control, cable entry sealing and packaging that survives the route.
3D Printer Frame Bracket Flatness Case File
An anonymised case file: a 3D printer frame bracket — gusseted stiffness, hole-position tolerance for rail alignment and a zinc finish.
Laboratory Instrument Chassis Aluminium Case File
An anonymised case file: a laboratory instrument chassis in aluminium — shielding continuity, thermal contact and a tooling-free low-volume build.
Send the drawing, get a real answer
An engineer reviews your model for manufacturability and returns a costed quotation — with the DFM observations that would change the price.