Case Details

Project Background

Longwang has developed a high-precision, lightweight aluminum alloy front operation panel for high-end intelligent handheld terminals and device controller OEM manufacturers. This project has tailored a precise stamping solution for a leading industrial vehicle and control terminal manufacturer in North America, which is used to manufacture industrial human-machine interaction (HMI) operation panels.

Through blanking, punching, flanging and CNC machining (countersinking & chamfering), Longwang successfully created a sturdy and smooth-touch control panel.

Core Refinement

Integrated U-shaped mounting structure: Formed from a single sheet via one-piece bending, with extended mounting legs and precision positioning holes for embedded installation into equipment housings, delivering stable alignment and strong load-bearing capacity.

Multi-functional opening array: Densely arranged rectangular slots, square holes and small round holes correspond to physical buttons, status indicators, DIP switches and interface sockets, matching the internal PCB layout with zero secondary drilling required.

Lightweight hollowed-out design: Profiled cutouts on both sides reduce overall weight by 18% while maintaining structural strength, and also support internal cable routing and auxiliary heat dissipation.

Manufacturing Challenges

• A 1.5 mm thick aluminum sheet requires uniform vertical flanging around two large circular holes. Improper die design or non-standardized stamping parameters can easily lead to edge cracking, uneven flange heights, or material thinning, directly compromising assembly precision and structural integrity.
• The panel features holes of various sizes distributed across a large surface area. The uneven stress distribution resulting from the stamping process makes the material prone to warping and waviness, causing it to exceed flatness tolerances.
• All buttons, indicators, and mounting holes must align perfectly with the internal PCB assembly; multi-step, separate hole-drilling processes can lead to cumulative positioning errors, resulting in misalignment during final assembly and necessitating on-site rework.

Longwang Solution

Hybrid Stamping + Precision CNC Milling Process: Longwang has devised a hybrid manufacturing solution that employs high-speed progressive stamping for blanking and main profile cutting, followed by 5-axis precision CNC milling to produce smooth 3D chamfers, grooves, and clean countersunk holes.

Sequential Stress Relief + Precision Flattening: Piercing and forming operations were arranged in an optimized sequence to balance internal material stress. A dedicated precision flattening station was added after forming to eliminate residual stamping stress, locking full-panel flatness within 0.08mm without secondary manual correction.

Completion of all hole punching in a single stroke: Utilizing a high-precision progressive die assembly, all functional holes are punched simultaneously at a single station, thereby eliminating cumulative positioning errors associated with multi-stage processing.

Results Achieved

• Panel flatness pass rate reached 99.3%, fully eliminating front face gap and PCB fit issues.
• Order lead time was shortened from 48 days to 15 days, reducing the client’s inventory cycle by nearly 70%.
• Overall dimensional pass rate reached 99.6%, with zero hole misalignment assembly failures reported in mass production.
• Salt spray corrosion performance reached 560 hours, exceeding the client’s 500-hour requirement and meeting long-term outdoor industrial service conditions.

Project Experience

This project demonstrates that the combination of precision aluminum stamping and CNC precision machining serves as a reliable alternative to traditional die-casting for industrial-grade cosmetic panels, delivering superior dimensional consistency, reduced weight, and significantly lower costs in mass production. This technology expands Longwang’s portfolio of proven solutions for industrial Human-Machine Interfaces (HMIs) and automotive electronics, while establishing a replicable process benchmark for thin-walled aluminum stamping that meets stringent requirements for surface finish, flatness, and corrosion resistance.

It also enables Longwang to supply control panels and handheld device housings that satisfy the most rigorous functional, ergonomic, and aesthetic standards demanded by global technology companies.