1. Product Background
The customer provided the drawing for an automotive compressor base, a structural stamped component used to support and secure the compressor assembly. Key requirements included:
- Material thickness: 1.8 mm
- Surface finish: Black powder coating
- Salt spray resistance: More than 72 hours
- Stable dimensions and reliable assembly performance
Because the part contains embossed features and multiple bends, the manufacturing process had to control deformation and dimensional variation throughout production.
2. Challenge
The main challenge was turning the customer’s drawing into a stable and repeatable production process. Key risks included deformation after multiple forming operations, accumulated dimensional variation, distortion around embossed areas, and surface defects that could affect the final coating and assembly.
For automotive parts, small variations can directly affect installation accuracy and batch consistency.
3. Solution
Based on the product structure and quality requirements, our engineering team developed and optimized the complete manufacturing process:
Material Slitting → Blanking → Embossing → Multi-Stage Bending → Visual Inspection → Powder Coating & Baking → 100% Final Inspection → Packing → Shipment
Instead of forming the part in one aggressive step, the final geometry is created gradually through controlled stamping and bending operations. This helps reduce deformation and improve dimensional stability.
Before powder coating, parts are visually inspected for forming and surface defects. After coating and baking, every finished part goes through 100% final inspection before packing.
Watch How This Automotive Compressor Base Is Made
[Automotive Compressor Base Manufacturing Process Video]
4. Result
The optimized process achieved:
- Stable forming quality
- Consistent black powder-coated appearance
- Reliable dimensional performance
- Salt spray resistance above 72 hours
- Stable batch production
The value of this project was not only making the part according to the drawing, but developing a process that could manufacture it consistently, efficiently, and reliably.
At Innoway Precision, we support custom automotive stamping and sheet metal projects from DFM and tooling to forming, surface finishing, inspection, and shipment.
FAQ
The part is manufactured from 1.8 mm sheet metal.
The finished part uses a black powder-coated finish.
The coating is required to withstand more than 72 hours of salt spray testing.
Multi-stage bending helps control deformation, reduce dimensional variation, and improve forming stability for complex 3D parts.
Yes. The finished parts go through 100% final inspection before packing and shipment.
Yes. We can support custom automotive brackets, compressor bases, structural stamped parts, and sheet metal components from drawing review to mass production.
