Customer：

Low volume manufacturing is a specialized service offering full production-quality parts but in volumes usually limited to 100,000 pieces or fewer, depending on the process used. This is an increasingly popular option for many product categories, allowing for a more limited investment in tooling and materials while providing quick access to markets, rapid response to shorter product life cycles and as a bridge between initial prototypes and high-volume production.

Customer Comments：

KANOU group has rich experience in the production and assembly of mechanical automation parts. Since the beginning of project, KANOU team players have shared their experience with us, in terms of small module assembly and parts processing, it not only meets the assembly requirements, but also prevents the cost waste.

Product：

This is a part used on the automatic production line of medical equipment assembly. Base on the characteristics of large-scale mass production of automatic production line, the product design process is advanced, stable and reliable, remaining unchanged for long time. Such products are more suitable for automatic production lines, including transportation, assembly, testing, packing, automatic control and other units.

Meanwhile, the reduction of labor force leads to the increase of labor cost, and it is urgent to speed up automatization of production line. Due to the characteristics of multiple varieties and small batches in the field of medical equipment, it’s necessary to consider not only the commonality of small modules, but also practicability, when promoting automatic production.

Project：

Since receiving the customer inquiry, we have made a detailed investigation and discussion. No matter the precision of parts or the tolerance after small die assembly, the tolerance of key dimensions of parts is controlled within ±0.002mm, and the tolerance after assembly is controlled within ±0.005mm. To achieve the tolerance, it is necessary to make comprehensive consideration in terms of materials, process arrangement, and the use of tools and machine tools.

Processing Highlights：

Challenge 1：

Material Selection：

1. To achieve exquisite appearance and uniform color difference, we make the surface to be anodized. Common 6061 has many impurities, which affect the appearance of anodization and is easy leading to material spots, so national standard materials purchasing is necessary.

2. It is easy to exceed the tolerance due to stress and deformation in 6061-T6 machining. Therefore, purchasing 6061-T651 to ensure that the product is not deformed, to achieve high accuracy in dimension.

Challenge 2：

Tool Selection

1.We choose Sandvik cutting tools to ensure product smoothness and accuracy.

2. It is easy to exceed the tolerance due to stress and deformation in 6061-T6 machining. Therefore, purchasing 6061-T651 to ensure that the product is not deformed, to achieve high accuracy in dimension.

Challenge 3：

4-axis CNC machining: Because it has 6-sided body shape, precision hole angle tolerance of each surface is required to be accurate, and 6-sided structure and angle tolerance are machined by Japanese Sankyo 4-axis turntable.

A: Deep hole processing: the minimum processing radius is R5 and depth 75mm. It requires high rigidity of the tools. We select Sandvik alloy coated milling cutter, matching perfect processing design, to ensure the accuracy and appearance of deep holes.

B: Deburring of cross holes: deburring with customized inner hole reverse chamfering knife.