Case Overview

This case presents a customized end-to-end manufacturing solution for home safe shells and security enclosure structures, developed and delivered by Dongguan Longwang Hardware Co., Ltd. for domestic smart security and home safe brands. Tailored to the characteristics of household scenarios — diverse product specifications, balanced requirements for security performance and home aesthetic fit, and frequent new product iteration — the solution integrates precision forming of medium-thick steel plates, traceless welding deformation control, and home-grade high-quality surface treatment, supporting full-cycle customization from design for manufacturability (DFM) optimization to mass production.

Case Details

Project Background

This case presents a customized end-to-end manufacturing solution for home safe shells and security enclosure structures, developed and delivered by Dongguan Longwang Hardware Co., Ltd. for domestic smart security and home safe brands. Tailored to the characteristics of household scenarios — diverse product specifications, balanced requirements for security performance and home aesthetic fit, and frequent new product iteration — the solution integrates precision forming of medium-thick steel plates, traceless welding deformation control, and home-grade high-quality surface treatment, supporting full-cycle customization from design for manufacturability (DFM) optimization to mass production.

Manufacturing Challenges

High-mix small-batch production with wide specification coverage

Home safe products cover a wide range of sizes from 200mm small desktop models to 1800mm large floor-standing models, with plate thickness ranging from 3.0mm to 8.0mm. Frequent production changeover easily causes dimensional fluctuations, making it difficult to balance production efficiency and precision consistency of each model.

Dual requirements for structural security and appearance delicacy

As household products, home safes need not only anti-pry and impact-resistant structural strength to meet security grade standards, but also flat and traceless appearance surfaces, uniform and delicate coating, and no obvious welding or processing traces, which puts forward higher requirements for welding and surface treatment processes.

Difficulty in controlling springback of composite thickness plates

The door panel and cabinet body of home safes usually adopt different thickness designs. The mismatch of springback amount of plates with different thicknesses easily leads to uneven door gaps and poor fit, which affects both sealing performance and product appearance quality.

Diversified customized demands and fast iteration rhythm

With the upgrading of home security demands, customized requirements such as fingerprint lock / password panel opening, built-in jewelry drawer structure, wall-in / embedded installation design and home-style color matching emerge in an endless stream. Suppliers are required to have fast DFM response and rapid prototyping capabilities.

Longwang Solution

• Equipped with high-power fiber laser cutting machines, Longwang has established a special process parameter database for home safe products covering 3.0–8.0mm steel plates. With standardized quick-change tooling solutions, production changeover efficiency is increased by 50%, while linear dimensional tolerance is stably controlled within ±0.2mm and bending angle accuracy within ±0.5°, ensuring consistent precision for both small-batch customized models and mass-produced mainstream models.
• A targeted graded welding scheme is adopted according to structural position: full-penetration CO2 gas shielded welding for anti-pry frames and lock bolt positions to ensure structural strength, and precision spot welding + fine polishing treatment for appearance surfaces to eliminate weld marks and achieve a flat and smooth shell surface. All assemblies are positioned by dedicated tooling, and shot blasting stress relief is performed after welding to control the overall flatness of the cabinet within 1.0mm/m², effectively solving the deformation problem of composite thickness plate welding.
• Relying on the 8-meter automatic spraying production line, all workpieces go through the full pretreatment process of degreasing, rust removal, phosphating and passivation. High-hardness matte TGIC polyester powder is applied by electrostatic spraying with coating thickness precisely controlled at 60–80μm. It supports full customization of RAL colors and textured / frosted finishes, with zero visible color difference between batches, scratch resistance and corrosion resistance, and salt spray resistance stably exceeding 500 hours, which meets both home aesthetic needs and long-term durability requirements.
• Longwang assigns a dedicated technical docking team, providing DFM optimization suggestions within 24 hours after receiving drawings. The rapid prototyping line shortens the sample delivery cycle by 40% compared with the industry average, and supports rapid verification of customized structures such as special openings, built-in installation beams and embedded designs, helping customers speed up new product launch.