Case Studies

Electric Vehicle Battery Tray Prototype

Technical Specifications:

Substrate: 6061-T6 aluminum, CNC machined to ±0.05mm
Brackets: CarbonPA™ (50% short carbon fiber), layer thickness 80μm
Connection: Laser welding + structural adhesive composite process

Verification Data:

Test Item	Standard Requirement	Measured Result
Bending Stiffness	>15kN·m/rad	18.7kN·m/rad
Salt Spray Test	1000hrs	No corrosion (1500hrs)
Thermal Cycling (-30~85°C)	100 cycles	200 cycles without deformation

Failure Analysis:
The initial design's weld point fatigue life was only 50,000 cycles. After microstructural optimization, it was improved to 200,000 cycles.

Surgical Navigation Fixture

Material Science:

Post-treatment: Plasma sterilization + nano-coating

Accuracy Verification:

CT Scan Comparison: 93% area error <0.05mm
In-surgery Navigation Data: Instrument positioning deviation 0.12±0.03mm

Biological Testing:

Cytotoxicity Test: Meets USP <87> Class VI
Bone Integration Rate: 78% after 6 weeks (compared to 52% for traditional instruments)

Drone Carbon Fiber Airframe

Process Details:

Mold: 7075 aerospace aluminum, hard anodized surface
Layup: 6 layers of T800 carbon fabric, vacuum bag molding
Curing: 80°C/6hrs + post-cure at 120°C/2hrs

Mechanical Properties:

Direction	Tensile Strength (MPa)	Modulus (GPa)
0°	3200	170
45°	150	8.5

Wind Tunnel Testing:

Critical Flutter Speed: Increased to 220 km/h
Aerodynamic Efficiency: Lift-to-drag ratio improved by 18%

Smartwatch Metal Mid-frame

Machining Parameters:

Machine: Swiss Bomi S191
Tool: Diamond-coated 0.2mm end mill
Cooling: Minimal Quantity Lubrication (MQL) technology

Surface Treatment:

Sandblasting: 120 mesh glass beads
Anodizing: Thickness 25±2μm, Hardness HV450

Cost Analysis:

Process	Unit Cost	Processing Time
Traditional Machining	$18.50	45min
FirstPart Solution	$9.80	22min

Notes: For the above cases, we have obtained the client’s consent and authorization.

CASE STUDIES