Aluminum Housings for On-Board DC-DC Converters
Aluminum housings and matching bushings for on-board converters, judged on seal-face flatness, wall consistency and appearance.
Requirement
The customer’s on-board DC-DC converter needs an aluminum housing where seal-face flatness decides the water ingress test. Inside, the housing must hold the power board and inductors with 2 mm walls and no distortion, while the outer surface is visible and must not show tool marks.
Our approach
Blanks are stress-relieved, roughed, semi-finished symmetrically and finished with light cuts to limit thin-wall movement. The seal face is milled separately and flatness-corrected, checked on a surface plate before assembly. Internal corners follow tool radius so no area is left uncut, and cosmetic faces run a high-speed finishing path.
Delivery and inspection
First batch of 30 sets with seal-face flatness records and notes for the leak test; full visual inspection on cosmetic faces.
Project summary
First-pass leak test rate improved and no distortion gaps appeared after assembly. Cosmetic faces were accepted without polishing, and the housing is now a platform part.
Products used in this project
For a similar project, send your drawing — we will check whether the existing construction can be reused or needs redesign.
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