High precision, full automation future trends in machined parts for electronics industry

Machining of parts has evolved over the decades from traditional techniques done by hand to a punched-tape system or numerical control (NC) before transitioning to a computer numerical control (CNC) process.

Today, CNC technology is adopted in almost every industry because of its advantages of precision and repeatability, especially in volume manufacturing. Going by market size, CNC machines are forecast to reach $126.27 billion by 2028, or at 7.5 percent CAGR from 2021, according to Grand View Research. This is attributed to "the rising need for minimizing operating costs and errors in machine components and increasing efficiency in manpower deployment."

Beginning 2021, there are five trends that are expected to pave the way for its greater accessibility and reliability, according to US-based manufacturing company Fast Radius. These include the option of adding more axes even to legacy machines for fewer setups and more cost savings, and the availability of universal bases or tables and reusable soft jaws. The growing use of robotics, in particular collaborative robots or cobots, advanced workforce training through visualization software integrated in CNC machines, and upgraded CAD/CAM software are the rest.

With smart manufacturing, other technologies come into play not only to boost productivity but flexibility as well while reducing costs in the long run. This is especially true for China, which has achieved the scale for mass manufacturing, but now has to recalibrate to also fill the need for "mass customization," according to knowledge platform Market Prospects.

This concept is flexible manufacturing, which allows factories to shift their capacity to demand at zero cost. In this system using a computer-integrated manufacturing (CIM) approach, CNC processing centers, and material storage and transportation can be managed and optimized to meet the requirement for small-batch machined parts.

Current efforts in China continue to focus on realizing such a business model with equal emphasis on high precision and full automation. Because despite developments in this field, Chinese companies continue to lag behind their foreign counterparts in terms of production technique and efficiency.

For machined parts, the standard tolerance grades that Chinese companies can offer are IT01, IT0, IT1, IT2, IT3 to IT18 and IT5 to IT12. To improve the precision of their machine tools in terms of size, shape and position, these manufacturers are adopting error detection and compensation technology, which is said to be an effective and economical solution.

They are also investing in advanced CNC machines. Huayi International Industry Group Ltd, for instance, spent $440,000 on new equipment in 2020. Liyang Hengyu Machining Co. Ltd installed four production lines worth $260,000 to increase production by 30 percent in the same year despite the pandemic. It plans to do so again in 2022, this time by 10 percent, but did not disclose if additional machinery acquisition is included. Shanghai-based Essence Fastening System, meanwhile, has announced that it is investing $250 million in a 26,680sqm facility for automotive metal parts in Zhenjiang in Jiangsu province.

In electronics, CNC machining is used in the production of casings, enclosures, heat sinks, PCBs and connectors for large to compact consumer electronics and electronic components. In semiconductors, it is adopted for processing wafer chucks and carriers, solder pad stencils and flex circuit stiffeners.

Suppliers interviewed by Global Sources Electronic Components attribute the growth of the machined parts market to 5G deployment, which has accelerated developments in mobile electronics, wearable devices and the automotive industry and boosted demand for parts and components.

Nearly a thousand companies in China provide machined parts and include foreign ones with production facilities there. Many operate close to their clients in the manufacturing cities of Shenzhen, Dongguan, Zhongshan, Suzhou, Hangzhou, Wenzhou, Qingdao and Tianjin.

Chinese enterprises have factories compliant with ISO 9001, 14001 and ISO/TS 16949 and ensure their products meet RoHS guidelines.

China-made machined parts

Chinese manufacturers cater mainly to the requirement in mobile and consumer electronics, and the automotive and solar power sectors for parts used for fastening, supporting, connecting, shielding and sealing purposes.

The range of materials include stainless steel, copper, steel, aluminum and brass for parts In the aluminum category, 6061, 6063, 6060, 2011, 7075 and 6082 alloys are commonly adopted, while austenitic, ferritic, martensitic and duplex types are the usual options in stainless steel.

Typical finishes are done via sandblasting, anodizing, polishing, electroplating, color plating, heat treatment, laser engraving, mirror polishing, chrome, passivation and highlighting.

Materials used in machining of parts come from the domestic supply, although requests for other sources are accommodated.

The cost of manufacturing inputs rose significantly in 2020, forcing most suppliers to quote higher by 10 percent to as much as 20 percent the following year.

In 2022, material costs may stabilize and keep further product price increases at bay.

Brass machined part

Goldenmay Metal Products Co. Ltd markets this GM0670 brass machined part for automotive, machinery and furniture applications. Product diameter is 5mm and length 35mm.

This RoHS-compliant component has a 300-piece minimum order requirement. Lead time is 10 days.

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Machined connector in any material

This Huayi-C48 offered by Huayi International Industry Group Ltd is a machined connector made of copper, aluminum, iron, carbon or stainless steel or brass. Surface finish options include anodized zinc, nickel, chrome, silver and gold plating.

The supplier requires a minimum order of 100 pieces. Lead time is seven days.

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Stainless steel cable clamp

Liyang Hengyu Machining Co. Ltd manufactures this Cable Clamp, machined from stainless steel or buyer-specified materials. This part can also be processed using forging or stamping. Its size is customizable.

The minimum order is 500 pieces for delivery within 25 days.

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Brass or stainless steel machined part

Shenzhen Maijin Metal Works Co. Ltd offers terminals, standoffs, spacers, captive screws and panel fasteners made of brass or stainless steel, which include this MJOA-049-0011 machined part.

An order of at least 2,000 pieces is required and has a 10-day lead time.

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