Views: 0 Author: Site Editor Publish Time: 2026-05-08 Origin: Site
Published: May 12, 2026 | Category: Case Study | Reading time: 5 min
When a world-leading home appliance brand needed a sheet metal fabrication partner capable of handling over one million precision enclosure units per year with near-zero defects, they turned to Dingyi Precision. Eight years later, that partnership remains stronger than ever.
This case study walks through how we achieved 1M+ units annually at a 0.2% defect rate using advanced laser cutting, CNC bending, robotic welding, and electrostatic powder coating under a single roof. The technical approach and quality systems described here are available for any OEM seeking a reliable custom sheet metal fabrication partner.
Our client, a top-5 global appliance manufacturer, faced a set of demanding requirements for their microwave oven enclosures — a high-volume consumer-facing component where every detail matters.
• Aesthetic consistency: Visible surfaces must maintain strict color uniformity across hundreds of thousands of units. Even minor color differences are unacceptable for a premium kitchen appliance.
• Structural precision at scale: Assembly interfaces must align perfectly across every unit. A 0.5 degree angle deviation in bending can cause production line stoppages, which are extremely costly at scale.
• Surface durability: The powder coating must withstand kitchen humidity, heat, and cleaning agents without degradation. A minimum 1000 hours of salt spray resistance is required.
• Capacity and reliability: Over 1 million units per year with zero tolerance for delivery delays. Previous suppliers struggled with inconsistent quality and missed deadlines.
Dingyi Precision's approach combines advanced equipment, digital process control, and integrated quality management to deliver precision at scale.
We deployed 15 high-power fiber laser cutting systems up to 6000W to process all enclosure blanks in a single pass. This eliminated the dimensional variation that multi-step processing introduces.
Parameter | Specification |
Cutting accuracy | ±0.2mm |
Maximum thickness | 20mm (carbon steel) |
Material utilization | 90% or higher |
Result: Every blank is dimensionally identical, eliminating variation before it enters subsequent production stages.
With 20 CNC press brakes including machines capable of handling workpieces up to 8.4 meters, we assigned dedicated tooling setups to this product line. Our dynamic angle compensation technology automatically adjusts for material springback in real time, maintaining consistent bending angles across every batch. Over one million units produced, this has resulted in zero assembly-line fitting issues.
For enclosure designs requiring welded joints, our 4 robotic welding stations delivered 99.5% or higher weld yield. Automation eliminates the inconsistency of manual welding, ensuring every joint meets both structural and aesthetic standards.
The color finish was a make-or-break requirement for our client. We applied electrostatic powder coating across 3 automated lines with strict process controls.
Parameter | Specification |
Coating thickness | 80-100 μm uniform |
Color difference (ΔE) | 1.5 or less |
Salt spray resistance | 1000+ hours |
Our phosphate-free ceramic conversion coating pretreatment improves adhesion by 30%, ensuring the finish stays intact for the product's full lifecycle.
Metric | Achievement |
Annual volume | 1M+ units |
Defect rate | 0.2% or less |
Delivery lead time | 30% faster than industry average |
Partnership duration | 8 years and counting |
On-time delivery rate | 98% or higher |
You don't need to be a global appliance giant to benefit from this level of manufacturing rigor. The same equipment, processes, and quality controls are available for your projects, whether you need 100 units or 100,000 units:
• Laser cutting with ±0.2mm precision on steel up to 20mm thick
• CNC bending for workpieces up to 8.4m in a single pass
• Robotic welding with 99.5% or higher yield rate
• Electrostatic powder coating with 1000+ hour salt spray resistance
• PLM+ERP integrated workflow for fast, traceable production
• ISO 9001, ISO 14001 and ISO 45001 certified quality management
• Flexible batch sizes from prototype to mass production
Q: What is custom sheet metal fabrication?
A: Custom sheet metal fabrication is the process of transforming flat metal sheets into specific parts or assemblies through cutting, bending, welding, and surface finishing. Dingyi Precision offers a complete in-house workflow from laser cutting to powder coating.
Q: How long does it take to get a sheet metal prototype?
A: Dingyi Precision can deliver prototypes within 24 hours for standard designs, leveraging our PLM system and in-house tooling for rapid turnaround.
Q: What industries does Dingyi Precision serve?
A: We serve the appliance, HVAC, liquid cooling, energy storage, electrical control, and smart home industries, among others requiring precision sheet metal components.
Q: What quality certifications does Dingyi Precision hold?
A: Dingyi Precision is ISO 9001, ISO 14001 and ISO 45001 certified. Our powder coating meets RoHS and REACH standards.
Q: Can Dingyi Precision handle both low-volume and high-volume production?
A: Yes. Our PLM+ERP integrated system allows flexible batch sizes from 100 units for pilot runs to 1M+ units for mass production.
Q: Where is Dingyi Precision located?
A: Our manufacturing facility is in Foshan, Guangdong, China — a major industrial hub with excellent logistics connectivity to global ports.
Request a quote or download our capability brochure to learn how Dingyi Precision can support your custom sheet metal fabrication needs.
Phone: +86-13928890054
Email: niewenhui@dingyiprecision.com
