Ironvale · Contract manufacturing · Pune · Monterrey · Austin

From flat sheet to finished product. Under one roof.

Sheet metal, machining, finishing and box-build assembly for OEMs — engineered, built and inspected in our own facilities.

Get a quote in 24 hours Upload your drawing

A manufacturing engineer replies within 1 business day.

  • Overall 420 × 280 × 160 mm
  • Display cut-out ±0.05 mm
  • Finish RAL 9002 · 80 µm

Now watch us make it.

01

Laser cutting

A 2 mm CRCA steel blank is cut on a 6 kW fiber laser — vents and display window included.

  • Nitrogen-assist cut: clean, oxide-free edges
  • Nested to cut the blank with under 6% scrap
  • Every part laser-marked with a traceable ID

02

CNC bending

Four flanges are formed to 90° on a CNC press brake in a single setup.

  • Four flanges formed in one setup, no re-clamping
  • Bend angle checked in-process to ±0.5°
  • Bend radius set by tooling, not by hand

03

Hardware & welding

M4 PEM studs are pressed in; corners are TIG-welded and dressed.

  • Six M4 PEM studs pressed and pull-tested per panel
  • TIG corners welded, interpass kept below 150 °C
  • Welds dressed flush and checked for porosity

04

Powder coating

Pre-treated and powder coated for a durable, even finish.

  • Iron-phosphate pre-treatment before any coating
  • Electrostatic spray to an 80 µm film, RAL 9002
  • Cured in an oven ramped to 180 °C

05

Assembly & inspection

Lid, front panel and electronics are fitted, and every unit is tested before it ships.

QC PASSED

  • Lid, front panel and LED fitted at one station
  • Twelve-point functional test before release
  • Serial number logged against the test record

01

Laser cutting

A 2 mm CRCA steel blank is cut on a 6 kW fiber laser — vents and display window included.

  • Nitrogen-assist cut: clean, oxide-free edges
  • Nested to cut the blank with under 6% scrap
  • Every part laser-marked with a traceable ID

Fiber laser · ±0.05 mm

02

CNC bending

Four flanges are formed to 90° on a CNC press brake in a single setup.

  • Four flanges formed in one setup, no re-clamping
  • Bend angle checked in-process to ±0.5°
  • Bend radius set by tooling, not by hand

Bend · 90.0° ±0.5°

03

Hardware & welding

M4 PEM studs are pressed in; corners are TIG-welded and dressed.

  • Six M4 PEM studs pressed and pull-tested per panel
  • TIG corners welded, interpass kept below 150 °C
  • Welds dressed flush and checked for porosity

M4 PEM × 6 · TIG corners

04

Powder coating

Pre-treated and powder coated for a durable, even finish.

  • Iron-phosphate pre-treatment before any coating
  • Electrostatic spray to an 80 µm film, RAL 9002
  • Cured in an oven ramped to 180 °C

RAL 9002 · 80 µm

05

Assembly & inspection

Lid, front panel and electronics are fitted, and every unit is tested before it ships.

  • Lid, front panel and LED fitted at one station
  • Twelve-point functional test before release
  • Serial number logged against the test record

100% functional test

Capabilities

Everything between a drawing and a shipped product.

Six processes, run on our own lines in three facilities. Each one is set from your drawing and checked before the next step starts.

Industries

Built for six demanding industries.

The enclosures and frames we make every week, and the parts that go inside them.

Materials & tolerances

Five materials, tolerances you can plan around.

Typical values for production sheet parts. Your drawing sets the tolerance; these are the defaults we quote against.

Sample typical values
Material Thickness range Typical tolerance Common finishes
CRCA steel 0.8–3.0 mm ±0.10 mm laser · ±0.5° bend Powder coat, zinc plate
Galvanised steel 0.8–2.5 mm ±0.15 mm laser · ±0.5° bend Clear chromate, powder coat
Stainless 304 / 316 0.8–3.0 mm ±0.10 mm laser · ±0.5° bend Passivation, brushed #4
Aluminium 5052 / 6061 1.0–6.0 mm ±0.15 mm laser · ±0.5° bend Clear or black anodise, powder coat
Copper C110 0.5–3.0 mm ±0.10 mm laser · ±0.5° bend Tin plate, bare

Facilities

Three sites, 260,000 ft² of floor.

One quality system and one set of work instructions across all three sites, so a part qualified in one can be built in another.

Quality

Inspected at every step.

Four gates between incoming steel and the box on the pallet. Each gate keeps its own record, and the records ship with the lot.

  1. Gate 01

    Incoming material certs

    Mill certificates are checked against every heat and coil before cutting starts.

  2. Gate 02

    In-process SPC checks

    Critical dimensions are sampled on the line and charted, and parts are held when a reading drifts toward a limit.

  3. Gate 03

    CMM first article

    The first part off every new setup is measured in full on a coordinate measuring machine.

  4. Gate 04

    100% functional test

    Every unit is powered and exercised on a test rig before it leaves the building.

On-time delivery, 2025
98.7%
Sample defect rate, 2025
32 ppm
Typical quote response
1 day
Years building parts
18

Certifications · sample data

  • ISO 9001
  • IATF 16949

Quoting

How a quote works.

  1. Step 01

    Send your drawing

    Upload a STEP, DXF, DWG or PDF with quantities and target finish. A rough sketch is enough to start.

  2. Step 02

    DFM review within 24 h

    An engineer checks bend radii, hole spacing and tolerances, and flags anything that drives cost.

  3. Step 03

    Quote with lead time

    You get a fixed-price quote, a lead time and the DFM notes. Nothing starts until you approve it.

Get a quote in 24 hours

Resources

Guides for parts that build well.

Frequently asked questions

Sample answers for this concept demo.

What is the minimum order quantity?

Prototype runs start at one unit. Production orders typically start at 50 units, and smaller batches are quoted case by case.

Which file formats do you accept?

STEP and DXF are preferred for geometry, with a PDF drawing for tolerances and finishes. Native DWG and SolidWorks files are accepted on request.

What is the typical lead time?

Prototypes take 5 to 7 business days. Production orders take about 3 to 4 weeks after approval, depending on finish and quantity.

Which certifications do you hold?

All three sites run under ISO 9001 and IATF 16949. These are sample certifications for this demo.

How do you ship, and which incoterms do you use?

We ship by LTL freight or parcel and quote DAP (delivered at place) as standard. EXW and FCA are available if you use your own forwarder.

Can you make prototypes before committing to tooling?

Yes. Prototypes come off the same laser and press-brake routes as production, so the first run tests the real process, not a hand-built stand-in.

Your drawing. Our floor. One partner.

Send a drawing or a rough idea. We'll come back with a DFM review and a quote.

Get a quote in 24 hours Upload your drawing

Concept demo by UnitOne AI · company name and figures are sample data