LS マニュファクチャリングは、精密な曲げ加工と曲げ後の表面処理工程を組み合わせることで、造船業界向けのカスタム コーティングされた金属部品の供給の刷新において船舶機器大手を指導しました。そして二次アウトソーシングが不要となるサプライチェーンの再構築に成功しました。また、1500 時間の中性塩水噴霧テストに合格した部品、特にコンポーネントの高応力領域が耐食性であることが確認されました。
超音波による多段階化学活性化が行われ、同時に 35μm のナノニッケルナノ絶縁層 + エポキシのジンクリッチ防食層構造が堆積されます。 Contour-based spraying ensures 100% coverage of the rounded corner coating.
Results and Value
This all-in-one solution completely abolished the secondary outsourcing, because of this cutting approximately 15% of hidden logistics costs, bringing the single-batch logistics loss rate down to 0.3%, and the cycle time was shortened to 9 days only. Corrosion-resistant bent parts from this batch of bent part coating service passed the 1500 hours of neutral salt spray as per ASTM B117.
The bending coating quality was so good that it went to the top levels of industry standards with red rust and peeling being zero at the high stress bending areas, and with adhesion, the grade was ISO 2409 Grade 0. In the end, the client signed a contract with LS Manufacturing to be the only strategic one-stop manufacturer for their mid-term global supply chain.
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One-stop integration can simultaneously improve corrosion resistance and optimize supply chain costs. You can upload engineering drawings and performance requirements to obtain a customized one-stop solution and quotation for custom coated metal parts.
What Custom Metal Bending Manufacturer Technical Capabilities Are Required For High Risk Chemical Applications?
Custom metal bending manufacturers meet very high standards when it comes to handling chemical applications that involve high risk factors. For working on corrosion protection projects of metal bending parts in highly corrosive environments, some of the key requirements for these manufacturers include having dual system quality certification, being capable of performing complete non-destructive testing, and having fully automated, closed-loop dip coating production lines.
Specialty materials bending features
Materials used for pipelines or structural parts in chemical, pharmaceutical, or petrochemical industries include, aside from regular steel, specialty materials like Hastelloy, titanium alloys, and 316Ti stainless steel. These materials are not within the research scope of regular custom metal bending manufacturers in regard to bending material compatibility.
Because of this, they may end up causing excessive deformation or intergranular damage. Only a handful of bending process databases exist for these kinds of materials. We have the facility to bend as many as 20 different specialty alloys without affecting the bending grain structure.
Complete non-destructive testing system
In high-risk chemical scenarios, micro cracks may cause material leakage accidents, and full process non-destructive testing is an essential capability for bent part surface treatment. We have at our disposal magnetic particle testing (MT) and dye penetrant testing (PT) systems that help us detect any microscopic crack whenever and wherever it might occur with 100% accuracy after the bending process and before coating, because of this ensuring the entire batch of pipe fitting is stress-free in the core stress area. This is a very trustworthy way of validating bending safety in high risk chemical environments and effectively eliminating the risk of leakage.
Three core competencies outlined below should be the basis for those suppliers who intend to take on custom coated metal parts in high risk chemical environments:
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ISO 9001 and IATF 16949 dual quality system certifications.
Non-destructive testing capabilities like magnetic particle testing and penetrant testing.
A closed-loop surface treatment production line that meets environmental standards.
Figure 4: Worker in yellow gloves operating press brake to bend metal sheet.
How To Optimize Individual Batch Sourcing Costs For Custom Precision Bending With Integrated Coatings?
The key to reducing the single-batch sourcing cost of custom precision bending coated parts is a one-stop integration of the entire process. Normally, the eastern procedure (secondary packaging, cross-factory logistics losses, and quality claim premiums) will be eliminated if the eastern one-stop integration is realized. Here the two separate chains of bending and electroplating are merged into a single closed-loop production.
Hidden procurement costs composition and decomposition
The hidden procurement costs in supply chain management can cause the purchase cost (unit price) to be relatively minimal. Typically, cross-factory logistics, repackaging, and claims and delays due to shifting of liabilities are the main causes of around 15% -20% of the total bending sourcing cost for custom precision bending. Still, these aspects are very much overlooked by the procurement personnel.
The cost differences between the traditional dual-supplier model and the one-stop integrated model can be seen in the table below:
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Cost Dimensions
Traditional Dual-Supplier Model
One-Stop Integrated Model
Cost Optimization Range
Cross-Plant Logistics Costs
Per Unit Cost 8%
0
100%
Packaging Losses
Per Unit Cost 4%
0.5%
87.5%
Quality Claim Costs
Per Unit Cost 6%
1%
83.3%
Delivery Cycle Costs
22-Day Cycle Corresponding Capital Cost
9-Day Cycle Corresponding Capital Cost
Approximately 59%
Total Hidden Cost Percentage
Approximately 18%
Approximately 1.5%
Approximately 91.7%
Unfortunately, most of the companies do not realize that the impact of bending hidden expenses on the total procurement costs is much higher than the difference in unit prices.
Path to Cost Reduction through One-Stop Integration
One-stop integration means a bending and surface treatment in the same factory area, which can eliminate all cross-plant handling links. At the same time, one supplier who takes the full quality responsibility, that means, avoiding delays and costs from claims due to buck-passing between factories, is the main direction for cost reduction and efficiency improvement in metal bending finishing service. This optimization of the bending supply chain is capable of shortening bending lead times a lot and raising supply chain responsiveness.
In general, a combination of post bending finishing service can help reduce costs in three main areas:
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Getting rid of turnover losses: Eliminating hidden expenses like cross-factory logistics and secondary packaging.
Delivery time reduction: Minimizing capital costs related to inventory holding and project delays.
Single point of quality responsibility: Preventing claims and rework costs resulting from the buck-passing between factories.
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The benefits of hidden cost optimization far exceed unit price reductions. You can provide your existing procurement parameters, and we will calculate the overall cost optimization potential of a one-stop custom precision bending solution free of charge.
Why Is Checking Vendor Testing Validation The Non Negotiable Final Step In Professional Custom Metal Framing Supplier Inspection?
The review of a supplier's testing validation report is considered the final defense to confirm that a custom metal framing supplier is a professional one. The buying party should ask the supplier for cross-cut adhesion test results, complete surface film thickness maps, and batch salt spray data logs, without accepting a spoken promise without evidence.
Main Elements of Documentation for Factory Quality Inspection
The quality of surface coating is taken as a given, short-term corrosion resistance can be tested by the human eye. The bending quality documentation of a metal supplier, professional in the framing sector, needs four main elements: measurements of dimensions, evaluation of the release of stress, measurement of thickness by an X-ray thickness gauge at the bend fillet area, and the results of adherence tests.
Major Verification Aspects for In-Person Factory Audits
Factory on-site audit should be the time for purchasing people to check if the supplier has a separate salt spray testing lab and an environmental simulation chamber. Only factories with fully closed-loop bending test abilities can make sure that the corrosion resistant coated bending in production is consistent, and performance differences between samples and mass-produced parts are avoided. Independent testing is the fundamental core to guarantee bending production consistency and can erase the problem of manipulated samples that third-party submit.
Three core aspects need to be checked when evaluating the quality control capability of the bent part coating service supplier:
Does the supplier own equipment for salt spray testing and environmental simulation that are independently operated?
Is the supplier able to provide the three-coordinate measurement of the film thickness surface for the respective batch?
Is the supplier capable of providing records of stress annealing and pretreatment processes which are complete?
FAQs
Q1: What is the main reason to get post bending finishing service instead of pre-coated bending?
Pre-bending coating offers 100% complete bending coating coverage and secures the bending zone from micro tensile cracks, so there is no longer the risk of early localised perforation and red rust formation resulting from anti-corrosion layer cracking after bending of the pre-coated sheet.
Q2: What practices does LS Manufacturing implement to guarantee that the anti-corrosion coating perfectly adheres to bent surfaces under high stress?
We make sure that the bonding strength of the anti-corrosion coating in the bending deformation zone reaches Grade 0 (5B) level by carrying out 320℃ vacuum stress-relief annealing to remove the lattice residual stress immediately after bending, and thereafter doing ultrasonic multi-stage chemical activation to remove contamination.
Q3: Which exact technical standards do you utilize for the testing of corrosion-resistant coated bending parts?
We carry out our tests in compliance with the internationally recognized ASTM B117 and ISO 9227 neutral salt spray test standards and use as an additional measuring tool the ASTM D3359 cross-cut adhesion test and eddy current 3D coordinate measuring machine metal thickness measurement to be certain that the components are subjected and passed to the bending corrosion validation test conditions of extreme environments.
Q4: Could you make the coating layer thickness different/variable at certain parts of the custom-coated metal components so that the assembly tight clearance is met?
In fact, we operate CNC servo spraying together with contour masking customized for the particular shape to keep an anti-corrosion coating thickness of more than 25μm in the most vulnerable bending areas while at the same time tightly controlling the assembly sealing film thickness within 10μm to satisfy the requirements of precision assembly.
Q5: What is the average time frame for a metal bending finishing service project at LS Manufacturing?
The main reason is that we have bending, heat treatment, and coating lines in one factory. Because of this, the total delivery time for medium to large-volume orders can be cut drastically from the conventional 14-21 days totally across various factories to only 7-10 days.
Q6: How do you ensure that anti-corrosion bent parts do not suffer from hydrogen embrittlement during the final treatment stage?
At the chemical cleaning part, we totally give up the strong inorganic acid etching process which poses a high risk of hydrogen embrittlement simultaneously with the help of ultrasonic stripping technology, we use mild organic acids to prevent the hydrogen atoms from entering high stress bending areas, basically we stop the source of the problem.
Q7: Do you have a minimum order quantity (MOQ) for high end bent part coating service orders?
We do not impose a minimum order quantity for services of industrial-grade production of bent parts with coating under our one-stop solution even if the production order is for less than 10 prototype samples. Whether the production order is for a long-term mass production of tens of thousands of units, we can provide flexible capacity matching.
Q8: How can I obtain an accurate quote for fully integrated custom precision bending and post bending coating?
You can upload 3D drawings (supporting STEP/IGS/DWG formats) via our official secure encrypted channel, and the material, bending radius, and salt spray corrosion resistance requirement. Our technical personnel will provide you with a comprehensive quotation including a DFM analysis within 24 hours.
Summary
In high value industrial B2B manufacturing scenarios, the traditional supply chain model that separates bending and anti-corrosion surface treatment is gradually being replaced by the mid-to-high end market as microscopic defects like bending stress cracking and coating embrittlement become known.
Finishing services after bending are able to remove residual stress, cover fully the bending microcracks and even control micron-level tolerances. Both data and case studies justify that the manufacturing of bending + post-treatment under one roof is a scientific route for industrial enterprises to address premature corrosion of parts and reduce total cost of ownership.
Do not allow surface treatment defects of simple, separate processes at the low-end to shorten the product life of your costly equipment. LS Manufacturing presents a one-stop closed-loop solution combining DFM collaborative design, CNC servo precision bending, vacuum stress-relief annealing and post bending coating to salt spray grade 1500 hours.
Contact our team of technical experts or upload your 2D/3D engineering drawings (STEP IGES PDF format) to get a free DFM manufacturing feasibility assessment and a one-stop mass production quote. We assure a tailored technical solution from our engineers within 24 hours, giving you strong quality support for your rise in the high end industrial market.
The contents of this page are for informational purposes only. LS Manufacturing services There are no representations or warranties, express or implied, as to the accuracy, completeness or validity of the information. It should not be inferred that a third-party supplier or manufacturer will provide performance parameters, geometric tolerances, specific design characteristics, material quality and type or workmanship through the LS Manufacturing network. It's the buyer's responsibility. Require parts quotation Identify specific requirements for these sections.Please contact us for more information.
LS Manufacturing Team
LS Manufacturing is an industry-leading company. Focus on custom manufacturing solutions. We have over 20 years of experience with over 5,000 customers, and we focus on high precision CNC machining, Sheet metal manufacturing, 3D printing, Injection molding. Metal stamping,and other one-stop manufacturing services. Our factory is equipped with over 100 state-of-the-art 5-axis machining centers, ISO 9001:2015 certified. We provide fast, efficient and high-quality manufacturing solutions to customers in more than 150 countries around the world.少量生産でも大規模なカスタマイズでも、24時間以内の最速納期でお客様のニーズにお応えします。 choose LS Manufacturing. This means selection efficiency, quality and professionalism. To learn more, visit our website:www.lsrpf.com.
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