Case Studies
Discover how Carsai Precision Parts supports global customers with custom metal parts and busbar solutions.
1. Tin-Plated Copper Busbars for Power Distribution Units
Project Overview
A U.S.-based telecom equipment contractor required tin-plated copper ground bars for grounding and bonding in telecom power distribution systems.
The ground bars were installed inside cabinets and racks, requiring reliable conductivity, accurate hole patterns, and consistent tin plating quality.
Challenges
- Precise hole positioning for grounding cables and terminal lugs
- Uniform tin plating to ensure stable electrical contact
- Burr-free edges for safe installation inside telecom cabinets
Our Solution
Precision punching and forming, controlled tin plating, and 100% inspection for dimensions, hole alignment, and surface finish
Result for Customer
- Stable grounding performance in telecom systems
- Smooth installation during cabinet and rack assembly
- Long-term repeat orders from the U.S. telecom customer
2. Custom Powder-Coated Steel Mounting Brackets for Telecom Cabinets
Project Overview
A telecom equipment manufacturer required custom aluminum mounting plates to support and secure ground bars inside power distribution cabinets.
The plates needed accurate hole alignment and clean surface finish to ensure reliable grounding connections.
Challenges
- Precise hole alignment for grounding bar installation
- Burr-free edges required for safe electrical contact
- Fast delivery for cabinet system launch
Our Solution
- Precision-fabricated aluminum mounting plates with tight tolerances
- Deburring and optional anodizing for corrosion protection
- Full inspection for hole alignment and mounting accuracy
Result for Customer
- Perfect alignment for ground bar assembly
- Delivered 30,000 pcs in 7 days
- Improved grounding stability
3. Custom Aluminum Mounting Plates For Grounding Systems
Project Overview
A telecom equipment manufacturer required custom aluminum mounting plates to support and secure ground bars inside power distribution cabinets.
The plates needed accurate hole alignment and clean surface finish to ensure reliable grounding connections.
Challenges
- Precise hole alignment for grounding bar installation
- Burr-free edges required for safe electrical contact
- Fast delivery for cabinet system launch
Our Solution
- Precision-fabricated aluminum mounting plates with tight tolerances
- Deburring and optional anodizing for corrosion protection
- Full inspection for hole alignment and mounting accuracy
Result for Customer
- Perfect alignment for ground bar assembly
- Delivered 30,000 pcs in 7 days
- Improved grounding stability
4. Custom Sheet Metal Enclosures & Covers
Project Overview
A German electronics company required custom sheet metal enclosures and covers for electrical equipment.
The enclosures were manufactured from SPCC steel and aluminum and used to protect internal electrical components.
Challenges
- Multiple fabrication processes required
- Cosmetic surface quality requirements (no dents or scratches)
- Precise alignment for screw positions and assembly
Our Solution
- Integrated stamping, CNC bending, and TIG spot welding
- Powder coating with consistent surface finish
- Inspection to control assembly deviation
Result for Customer
- Achieved a clean and professional surface appearance
- Consistent dimensional accuracy across batches
- Reduced customer assembly time by 30%
5. Precision Brass, Copper & Tin-Plated Terminal Lugs
Project Overview
A U.S. telecom customer required custom brass and tin-plated copper terminal lugs for grounding and power connections.
These terminal lugs were used together with ground bars and busbars in electrical and telecom systems, requiring tight tolerances, smooth edges, and reliable plating quality.
Challenges
- ±0.03 mm thread tolerance
- Small-part deformation risk
- High conductivity and plating durability required
Our Solution
- CNC turning/milling for precise threads and holes
- Uniform 8–12 μm electro-tin plating
- Post-polishing for improved electrical contact
- 100% inspection of threads and plating
Result for Customer
- Zero assembly issues
- Strong, stable electrical connection
- Repeat monthly production orders
6. Precision Aluminum Panels for Electrical Systems
Project Overview
A European industrial automation company required precision-machined aluminum equipment panels for a high-precision electrical assembly system.
The panels were used for mounting sensors and control components, requiring complex pockets, tight hole tolerances, and strict flatness specifications.
Challenges
- Tolerance requirement tighter than ±0.01mm
- Multiple machining steps (milling, drilling, reaming)
- Surface uniformity required for sensitive sensor installation
Our Solution
- Used high-precision 4-axis machining centers
- Implemented double-fixture clamping to minimize deformation
- Final inspection with CMM (0.001mm accuracy)
Result for Customer
- 100% of parts passed quality inspection
- Assembly efficiency increased due to improved surface flatness
- Customer expanded to monthly production orders
⭐7. One-Stop Manufacturing for Multi-Process Industrial Assemblies
Project Overview
A European industrial equipment company required a series of custom components that combined CNC machining, sheet metal fabrication, stamping, welding, and final assembly.
Challenges
- Multiple materials required: aluminum, stainless steel, and brass
- Parts came from several suppliers → tolerances did not match
- Assembly deviation caused mechanical vibration
- Slow delivery due to multi-supplier coordination
Our One-Stop Solution
Carsai Precision integrated the entire production chain:
🔹 CNC Machining
High-precision aluminum blocks (±0.01mm) with threaded holes and milled pockets.
🔹 Sheet Metal Fabrication
Laser-cut and CNC-bent stainless steel covers and structural brackets.
🔹 Stamping & Punching
Progressive die stamping for high-volume copper and brass connectors.
🔹 Welding & Assembly
Spot welding, riveting, and sub-assembly performed in-house to ensure perfect fit.
🔹 Full Quality Control
100% dimensional measurement
Matching tolerance control across all parts
Assembly test before shipping
Result for Customer
- ✔ All components achieved perfect cross-process tolerance match
- ✔ Assembly vibration reduced by 70%
- ✔ Lead time shortened by 12 days (no more multi-supplier coordination)
- ✔ Customer cost reduced by 18%
- ✔ The client moved all 5 product lines to us after the first project
Applications
Automation equipment, industrial assemblies, machine frames, precision connectors.
All processes were managed under our quality control system to ensure consistent cross-process accuracy.