本手册借鉴了 LS Manufacturing 12 年机器人金属焊接经验，重点是通过实际实施案例和准确的工艺数据为机器人公司提供可行的金属焊接选择解决方案。我们已服务超过30个全球顶级机器人品牌，完成超过1000个定制金属焊接项目。我们约45%的案例是7075铝合金底盘焊接，我们的焊缝一次通过检验成功率始终在99%以上。
我们的工艺标准明确符合 ISO 3834-2 的焊接质量体系要求。此外，我们的焊接工程师均获得IIWIWE国际焊接工程师认证，确保每条焊缝均符合精密制造标准。
例如，一家财富 500 强仓库机器人公司的目标是到 2025 年利用 7075 铝合金将其下一代 AMR 底盘减重 40%。传统供应商的焊缝裂纹率为15%，导致10万次满载振动测试失败。 LS Manufacturing 投产后，焊接裂纹率降低了 0.8%，底盘重量减轻了 42kg，提前三个月开始量产，并节省了 20% 的售后成本。
我们的解决方案贯穿从DFM审核到批量生产的全程连续性，帮助客户降低整体采购成本15%-25%。与 ISO 13485 标准建立项目联盟。
Welding engineers must be holders of IWE (International Welding Engineer) certificate authorized by IIW in order to guarantee that the operations are carried out at a high level of expertise.
Should provide comprehensive radiographic or ultrasonic flaw detection reports confirming that the key welds are devoid of internal defects.
Maintain extensive welding parameter records that enable the parameters of each individual welding operation to be both searchable and traceable.
The company should have a comprehensive traceability system that would allow verifying each step from chassis welding to delivery.
Benefits of LS Manufacturing's Quality Traceability System
LS Manufacturing in fact came up with the first traceability system with "one piece, one code". Just by scanning the code, users can trace the entire background of a product through different stages including, for example, welding engineers, welding parameters, flaw detection reports, etc.
Protolabs have really good supply chain management but the problem is that the supply chain and the factory at the physical level are not connected, that is why there are so many quality control points on the production line and the factory risks are really high.As LS Manufacturing is the physical factory, it can directly control every welding process.
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In depth quality traceability can reduce welding quality risks and guarantee the reliability of the product. Users are offered to download LS Manufacturing's quality traceability checklist template to assess their present suppliers and to effortlessly pick the most appropriate partners.
What Technical Factors Determine The Service Life Of Lightweight Chassis Metal Welding Under Harsh Working Conditions?
The most crucial factors for the lifespan of lightweight metal chassis welded structures are the elimination of residual stresses, weld quality, and the mechanical properties of materials. Residual stress is the variable that significantly impacts the chassis and if it is not addressed, it may lead to the distortion of chassis and cracking of welds.
Impact of Residual Stress on Chassis Longevity
The post welding residual stress in a chassis acts as a slow poison and causes continuous degradation of chassis (deformation, cracks) especially when the downtime is prolonged, thereby shortening its life span. In simple terms, residual stress in a chassis is almost like "latent danger".
LS Manufacturing's Approach to Residual Stress Relief
LS Manufacturing uses Vibration Resin Aging (VSR) process to release residual stresses which is 85% effective (point of reference). Along with artificial aging, the mechanical characteristics of the material are restored and the life of the chassis manufactured by the technique is more than 10 years. Jabil and Protocollabs natural aging lead less than 50% stress relief, and even the chassis inside have cracksthat require repairs and pose expenses.
Figure 3: Laser-cut steel brackets and base plates for robotics applications.
Why Is LS Manufacturing Your Most Reliable Precision Welding Partner In 2026?
The right choice would be LS Manufacturing due to its skilled methods, wide range of products, and rich experience. LS Manufacturing has at its disposal more than 50 welding robots and a top notch process R&D laboratory that can be used to rapidly fulfill the custom metal welding service requirements at any time. It can weld not only 1.5mm thin walled aluminum alloys but also 7075 aluminum alloys while keeping the deformation rate below 0.8% and the tolerance at 0.3mm.
We provide services upstream from the DFM review stage all the way to the mass production stage, averting over 30 world leading robot brands to achieve overall procurement costs reduction by 15%-25%, manufacturing cycle time shortening by 15-20 days, and maintaining a first pass weld inspection success rate at a level always exceeding 99%. Our company has become a top global robot brands' principal welding partner.
常见问题解答
Q1: Are you capable of welding ultra thin chassis with a thickness of less than 1.0mm?
Yes, we are capable of that. We employ ultra low heat input CMT welding in conjunction with precision air cooled fixtures which allows us to stably weld 0.8mm aluminum alloy without perforation, the welding deformation rate is 0.8%, fulfilling the high precision requirements.
Q2: Is 100% weld inspection included in your robotics metal welding services?
We can offer X-ray or ultrasonic testing if required, doing 100% inspection of core load bearing welds and producing a thorough report to confirm that the welds have no internal defects.
Q3: How do you maintain the dimensional consistency of customized welded chassis during mass production?
Besides laser tracking sensors + automated welding stations + high precision fixtures, we do real time correction with these, and that is how we ensure that the tolerance consistency of chassis feature positions in mass production is 0.3mm.
Q4: Is it possible for you to provide welding process qualification (PQR) support for customized needs?
We sure can. For special aluminum alloys like 6061 and 7075, we will do PQR/WPS qualification, then parameter optimization and lastly provide full qualification documentation.
Q5: What aluminum alloy type do you mainly recommend for welding lightweight chassis metal?
We generally recommend using 5052 aluminum alloy for welding since it is very easy to weld. If high strength is the concern, then the 6061 aluminum alloy is the way to go, and its mechanical properties can be recovered through aging treatment after welding.
Q6: Is the metal welding quotation from LS Manufacturing inclusive of a dedicated fixture development fee?
The fixture development charge is part of the first customized order. In case we establish a long term cooperation or the order volume reaches the target, we would consider sharing or fully refunding this fee.
Q7: Are you able to connect dissimilar metals (e.g. aluminum and stainless steel) on robot chassis?
Yes, by laser arc hybrid welding or special design of transition section, it is possible to join aluminum and stainless steel firmly, and the strength of the joint can be more than 85% of the base material.
Q8: Do you have enough welding capacity yearly to support our global mass production plan in 2026?
Certainly, we can support you. We currently operate 5 automated welding lines with a total annual capacity of over 60,000 sets. We are also capable of doubling our capacity in 3 months timeframe to cater to the global mass production requirements.
摘要
Robot lightweighting in 2026 will put a premium on the welding quality of aluminum alloy chassis as a competitive lever. Xometry Jabil etc. are great suppliers generally but when it comes to the specific field of ultralightweight and super precise components, LS Manufacturing with core CMT and FSW processes, deep DFM review, and full quality traceability is the best choice.
Do you worry about chassis weight reduction and welding precision challenges? Or maybe your current suppliers' capabilities do not satisfy 0.3mm tolerance level? Call LS Manufacturing Manufacturing's expert welding engineers to receive a complimentary welding DFM optimizatio report or initial quote assessment based on drawings, and leverage data to demonstrate why we qualify to be a core supplier for the world's leading robotics company in 2026.
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.不应推断第三方供应商或制造商将通过 LS Manufacturing 网络提供性能参数、几何公差、具体设计特征、材料质量和类型或工艺。 It's the buyer's responsibility. Require parts quotation Identify specific requirements for these sections.Please contact us for more information.
LS 制造团队
LS Manufacturing 是一家行业领先的公司。专注于定制制造解决方案。 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.我们为全球150多个国家的客户提供快速、高效、高质量的制造解决方案。无论是小批量生产还是大规模定制，我们都能以最快的24小时内交货满足您的需求。选择LS制造。 This means selection efficiency, quality and professionalism. To learn more, visit our website:www.lsrpf.com.
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