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Stamping & Laser Cutting of a High Strength Steel Battery Tray Bracket for the Automotive Industry

(click on thumbnail to enlarge)Battery Tray Bracket
Battery Tray Bracket

A customer in the automotive industry needed a resource that could provide a wide array of metal forming capabilities, in-house for a small quantity run. The battery tray bracket that they required was manufactured utilizing our 5 axis laser cutter to form the tailored blanks with finished trim. The high strength steel blanks were then stamped on a 200 ton hydraulic press, followed by CNC turning and milling. The tray components were assembled with 8mm nuts and resistance welding prior to having an e-coating applied. Quality control of this 95mm high, and 250mm long part was maintained through dimensional testing on our temperature controlled CMM, which verified that the required tolerances of ±.005" were met. The testing reports generated were used to complete the CoCs required by the customer.

At Sherwood Prototype, we perform all manufacturing processes in-house, including all tool design and manufacturing. This total control over production allows us to offer our customers superior quality products, with enhanced lead times. To learn more about this project, or the processes used to manufacture it, see the table below or contact us directly.


Stamping & Laser Cutting Project Highlights

Product Name
Battery Tray Bracket
Product Description
This bracket employs multiple forming techniques for use in the automotive industry.
Capabilities Applied/Processes
Primary:
Laser Cutting
  • Tailored Blanks
  • Finished Trim
CNC Machining
  • In house tool design and manufacturing
    to control quality and improve lead time
Stamping
  • Extrusions and hydraulic forming
Assembly
  • Resistance welding 8mm nuts
Secondary:
E-Coating
Equipment Used to Manufacture Part
200 ton Hydraulic Press
5 axis Laser
CNC Lathe
CNC Mill
CMM Measuring Machine
Overall Part Dimensions
Height: 95mm
O.D.: 250mm
Tightest Tolerances
Less Than ±.005"
Material Used
High Strength Steel
Material Finish
E-Coated per Customer specs
In process testing/inspection performed
CMM Inspection
  • Inspected on Temperature Controlled CMM
  • Detailed Inspection Reports Generated
Certificates of Conformance Provided to Client
Industry for Use
Automotive
Volume
250 assemblies
Delivery/Turnaround Time
6 weeks
Delivery Location
Georgia
Standards Met
Customer supplied print, 2D CAD Drawing

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