Project Overview

An automotive electronics customer needed five complete prototype assemblies for an upcoming trade show. The project included nearly 30 different custom parts made from ABS, aluminum, brass, sheet metal and silicone. With only one week available for production, the customer needed more than individual prototype parts. Every component had to be manufactured, finished, inspected and prepared for assembly within the same tightly controlled schedule. Because the finished products would be displayed at an exhibition, the customer also had strict cosmetic requirements. The exterior surfaces needed to be smooth, the painted finish had to be consistent, and visible defects could not be accepted. YS Rapid coordinated the different manufacturing processes, completed the five prototype sets on schedule and shipped them by express delivery. The prototypes arrived at the customer’s company in time for the trade show.

The Challenge: Five Assemblies and Nearly 30 Custom Parts

This automotive electronics prototype combined multiple materials and manufacturing processes in one product. The project included: · CNC-machined ABS housings and covers · CNC-machined aluminum components · CNC-turned brass shafts · Rapid sheet metal prototype parts · Custom silicone samples · Polishing, painting and other cosmetic finishing · Fit checking and complete prototype assembly The short lead time made production coordination particularly important. A delay or dimensional problem with even one component could prevent the complete product from being assembled. Our team therefore planned the project as a complete prototype assembly rather than treating each drawing as an independent part.

Rapid Technical Review and Production Planning

After receiving the customer’s 3D CAD files, 2D drawings, BOM and assembly information, our team reviewed the complete project. The engineering review focused on the manufacturing method for each part, material availability, critical dimensions, surface finish requirements and the relationship between mating components. We also identified the parts that could affect the overall assembly schedule, including housings, shafts, mounting components and internal sheet metal structures. Production priorities were then arranged so that machining, silicone sample production and surface finishing could proceed in parallel where practical. This early planning helped reduce waiting time between processes and left enough time for inspection and final assembly.

CNC Machining of ABS Housings

Several exterior housings and covers were CNC machined from solid ABS material. For five prototype sets, CNC machining offered a practical way to produce accurate plastic housings without waiting for injection mold tooling. It also allowed the customer to evaluate the product’s structure, dimensions, assembly and appearance using parts manufactured directly from the CAD data. After CNC machining, the ABS parts went through careful manual finishing. Machining marks, scratches and uneven transitions were removed before painting. This preparation was essential because paint does not hide poor surface quality. Small defects that are difficult to notice on an unfinished part can become more visible after coating, especially under the strong lighting commonly used at trade shows.

Machined Aluminum Components

The product also contained several aluminum components manufactured by CNC milling. These parts needed to align correctly with the ABS housings, brass shafts and sheet metal structures. Mounting holes, mating surfaces and other assembly features were inspected before the components moved to the finishing stage. Edges were deburred carefully, and visible surfaces were prepared according to the appearance requirements of the finished prototype.

CNC-Turned Brass Shafts

The brass shafts and other round components were manufactured by CNC turning. Although these parts were less visible in the final product, their dimensional accuracy was important to the function and assembly of the prototype. Shaft diameters, shoulders, overall lengths and mating areas were controlled to ensure that the parts fitted properly with the surrounding components. The turned parts were inspected before assembly so that any dimensional issue could be addressed without affecting the final schedule.

Rapid Sheet Metal Prototyping

Several brackets and internal structural parts were produced through rapid sheet metal fabrication. The production process included cutting, bending, deburring and fit checking according to the part design. Hole positions, bend locations and overall dimensions had to correspond with the mounting features on the CNC-machined components. Because the sheet metal and machined parts were managed within the same project, our team could check their dimensional relationship before final assembly.

Urgent Production of Silicone Samples

Several custom silicone components were also required for the complete prototype. Due to the low quantity and urgent schedule, the silicone samples were produced using rapid prototype tooling rather than full production tooling. This provided the required flexible components without adding a long tooling lead time. The silicone parts were checked for overall dimensions, hardness, flexibility, surface condition and fit with the surrounding components. Their production was coordinated with the CNC and sheet metal work to keep the complete project on schedule.

High-Quality Finishing for Exhibition Display

Trade show prototypes are inspected differently from ordinary engineering samples. In addition to demonstrating the product’s structure and function, they represent the customer’s design in front of potential buyers, distributors and project partners. The customer therefore required a very smooth surface and a high-quality painted finish. Before painting, the exterior components were polished and checked for: · CNC machining marks · Scratches or dents · Uneven surfaces · Inconsistent edges · Visible joining or transition lines · Dust and other surface contamination After painting, the parts were inspected again for colour consistency, coating coverage, surface texture and visible defects. Particular attention was given to the areas that would remain visible after assembly.

Assembly and Final Inspection

Once all components were completed, the five prototype sets were assembled and inspected as complete products. The final checks covered: · Part quantities and component identification · Alignment between housings and panels · Fit between machined, turned and sheet metal parts · Positioning of silicone components · Installation of shafts and internal structures · Mounting-hole and fastener alignment · Gaps and steps between visible surfaces · Paint quality and overall cosmetic appearance Checking the complete assemblies allowed minor fitting issues to be identified and corrected before shipment. This was especially important because the customer had very limited time available after receiving the prototypes.

Delivered in Time for the Trade Show

Despite the number of components, mixed manufacturing processes and strict cosmetic requirements, YS Rapid completed the five automotive electronics prototype sets within the required production schedule. The finished prototypes were carefully packed and shipped by express delivery. They arrived at the customer’s company in time for the exhibition, allowing the customer to present the new product as planned.

One-Stop Prototyping for Automotive Electronics Products

Automotive electronics products often combine plastic housings, precision metal components, sheet metal structures, silicone parts and cosmetic finishes. Managing these processes through separate suppliers can increase communication, dimensional and scheduling risks. YS Rapid provides coordinated prototype manufacturing through one project team. Our services include: · CNC machining of plastic and metal parts · CNC milling and CNC turning · Rapid sheet metal fabrication · Silicone prototype production · Polishing and painting · Silk-screen printing and laser marking · Fit checking and prototype assembly · Final inspection, packaging and international delivery

If you are developing an automotive electronic device, exhibition model or multi-part product prototype, send us your 3D CAD files, 2D drawings, BOM, quantities and required delivery date. Our team will review the complete assembly and recommend a practical manufacturing plan.