CNC machined battery box for an Austrila client

Project Background

A client from Australia ordered 6 sets of custom underwater communication circuit protection boxes (including the box body and cover) for testing and validating the protection effect of the internal electronic components in a real underwater environment at 30 meters depth. The material requirements were for high corrosion resistance and strength, and the delivery time was five days.

box cover 3d drawing

box body 3d drawing

Project Analysis

The major challenge of this project was to design and manufacture a protective box that could withstand the harsh underwater environment while ensuring the safety of the internal electronic components. The tight delivery schedule also added pressure to the project.

Material Selection

Based on the customer’s requirements, our engineers recommended using nylon with 20% glass fiber for the box body and aluminum alloy 6061 T6 for the box cover. These materials have excellent corrosion resistance and sufficient strength to withstand the underwater environment.

Detailed Processing Steps

Box Body

CNC milling: The nylon with 20% glass fiber material was cut into a block form to match the desired dimensions of the box body. Then, it was loaded onto a CNC milling machine, which used a cutting tool to carve out the interior space of the box.

CNC drilling: After the milling process, the CNC drilling machine was used to create holes for screws to attach the cover to the box body and to create openings for ports on the sides of the box.

CNC tapping: The screw holes were then tapped using another CNC machine to create threads in the nylon material so that the screws could be securely fastened.

Surface treatment: After machining, the box body was cleaned to remove any debris from the machining process. The surface was then sandblasted to provide a textured surface for paint adhesion.

Painting: A black paint designed to adhere to nylon was applied to the box body. The paint was left to dry completely before being inspected for quality.

Box Cover

CNC milling: Aluminium alloy 6061 T6 was cut to match the desired dimensions of the box cover. It was then loaded onto a CNC milling machine, which carved out the required shape and thickness for the cover.

CNC drilling: Similar to the process for the box body, holes for screws and ports were drilled into the cover using a CNC machine.

Surface finishing treatment: The surface of the cover was treated with a cleaning solution to remove any oil or dirt. It was then anodized using a black hard anodizing (thickness ≥50μ) process to enhance the corrosion resistance and durability of the cover.

Surface inspection: After anodizing, the cover was carefully inspected for any defects or surface imperfections before being assembled onto the box body.

Assembly and Testing

After completion of processing and surface treatment, the box body and cover were assembled and tested to ensure the protection performance met customer requirements.

finished box sets before packing

Overall, our skilled technicians used high-precision CNC machines and careful surface treatments to ensure that both the box body and cover met the customer’s requirements for strength, corrosion resistance, and accuracy. Despite the tight delivery schedule, we completed the project on time and delivered the products to the customer. The customer was satisfied with the product quality and protection performance and provided positive feedback on the timely delivery.

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