Custom Fabrication And Welding Manufacturing Service

Manufacturing Insight: Custom Fabrication And Welding

Manufacturing Insight: Custom Fabrication and Welding Capabilities

At Shenzhen Honyo Prototype, custom fabrication and welding represent a critical extension of our precision CNC machining services, enabling the seamless transition from individual components to fully integrated, functional assemblies. This capability is indispensable for rapid prototyping and low-volume production, where structural integrity, material compatibility, and dimensional accuracy directly impact design validation and performance testing. Unlike high-volume production welding, our focus centers on prototype-specific challenges: managing thermal distortion in thin-walled geometries, ensuring weld repeatability for iterative testing, and accommodating diverse material combinations demanded by complex engineering designs.

Our dedicated welding facility employs certified technicians operating advanced TIG (GTAW), MIG (GMAW), and resistance welding systems, all calibrated for the stringent tolerances required in R&D and pre-production environments. We prioritize metallurgical integrity through rigorous pre-weld analysis, including material compatibility verification and joint design optimization. This is particularly vital for reactive metals like titanium or aluminum alloys, where oxidation control and heat input management prevent porosity and maintain mechanical properties. Honyo’s proprietary fixturing methodology minimizes distortion in sub-1.0mm sheet metal assemblies, achieving positional accuracies within ±0.5mm across welded structures. All welds undergo in-process NDT validation via dye penetrant testing (DPT) or ultrasonic inspection (UT), with full traceability documentation provided for critical applications such as medical devices or aerospace test rigs.

Material versatility defines our competitive edge. We routinely process carbon steel, stainless steel (304/316/L), aluminum (6061-T6, 7075), copper alloys, and titanium (Gr2/Gr5), adapting gas shielding, filler selection, and amperage profiles to preserve base metal properties. For instance, our pulsed TIG protocols for 0.8mm 316L stainless steel tubing eliminate burn-through while maintaining crevice-free joints for fluidic systems. This precision ensures prototypes accurately reflect final product behavior under stress, thermal cycling, or pressure testing.

The following table outlines our core welding capabilities for prototype development:

| Process | Primary Materials | Thickness Range | Critical Application Strengths |

|————–|————————-|—————–|———————————————-|

| TIG (GTAW) | SS, Al, Ti, Cu | 0.5mm – 6.0mm | Zero-defect seams; thin-wall integrity; clean aesthetics |

| MIG (GMAW) | CS, SS, Al | 1.5mm – 12.0mm | Rapid assembly of structural frames; high deposition efficiency |

| Spot Welding | SS, Al, Ni alloys | 0.3mm – 3.0mm | Battery packs; electronics enclosures; minimal heat-affected zone |

Integration with Honyo’s CNC machining ecosystem allows us to deliver turnkey solutions—from milled brackets to welded subassemblies—within compressed timelines. Our digital workflow ensures weld joint locations align precisely with machined datums, eliminating fit-up errors that delay prototyping cycles. By combining AMADA welding robots for repeatable geometries with manual TIG for complex contours, we bridge the gap between design intent and physical validation. For engineers requiring functional prototypes that withstand real-world loads, Honyo’s fabrication and welding services provide the metallurgical confidence and dimensional reliability essential for informed design decisions.

Technical Capabilities

Custom Fabrication and Welding Capabilities at Shenzhen Honyo Prototype

At Shenzhen Honyo Prototype, our custom fabrication and welding services are built on advanced CNC machining technologies, enabling high-precision metal component production for industries requiring tight tolerances and complex geometries. Our expertise spans 3-axis, 4-axis, and 5-axis milling, as well as precision turning operations, supporting both prototyping and low-to-mid volume production runs. These capabilities are integrated with expert welding techniques to deliver fully assembled, durable metal structures and components tailored to client specifications.

Our 3-axis milling systems provide reliable performance for standard planar and prismatic parts, while 4-axis and 5-axis CNC machining centers allow for multi-sided machining with minimal setup changes. This enables us to produce intricate contours, angled features, and complex organic shapes commonly found in aerospace, automotive, and industrial equipment applications. The use of simultaneous multi-axis motion ensures superior surface finish, reduced cycle times, and enhanced dimensional accuracy.

Precision turning is performed on advanced CNC lathes equipped with live tooling, enabling mill-turn operations that combine rotational and milling processes in a single setup. This capability supports the production of complex cylindrical parts with off-axis features, reducing handling and improving repeatability. All turning operations are optimized for high accuracy and surface integrity, particularly in materials that are difficult to machine.

Tight tolerance machining is a core strength at Honyo Prototype. We consistently achieve tolerances down to ±0.005 mm on critical dimensions, supported by in-process inspection and final quality verification using coordinate measuring machines (CMM) and optical measurement systems. Our manufacturing environment is climate-controlled to minimize thermal variation, ensuring consistent results across production batches.

We work with a broad range of engineering metals and alloys, selecting materials based on mechanical performance, corrosion resistance, and machinability. Below is an overview of our standard material offerings and achievable tolerances across key machining processes.

| Material Category | Common Materials | Typical Tolerance (Milling) | Typical Tolerance (Turning) | Max Work Envelope (mm) |

|——————-|——————|—————————–|—————————–|————————|

| Aluminum Alloys | 6061, 7075, 2024 | ±0.01 mm | ±0.008 mm | 1200 × 800 × 600 |

| Stainless Steel | 303, 304, 316, 17-4PH | ±0.01 mm | ±0.01 mm | 1000 × 600 × 500 |

| Carbon Steel | 1018, 1045, 4140 | ±0.01 mm | ±0.01 mm | 1000 × 600 × 500 |

| Titanium Alloys | Grade 2, Grade 5 (Ti-6Al-4V) | ±0.01 mm | ±0.01 mm | 800 × 500 × 400 |

| Brass & Copper | C36000, C11000 | ±0.01 mm | ±0.008 mm | 600 × 400 × 300 |

In addition to machining, our welding services include TIG (GTAW) and MIG (GMAW) processes, primarily for stainless steel, aluminum, and carbon steel assemblies. Welding procedures are qualified to international standards, with welders certified to ASME and ISO 9606 requirements. Post-weld machining ensures final dimensional compliance, especially for hybrid components requiring both structural integrity and precision fit.

Shenzhen Honyo Prototype combines advanced CNC technology, rigorous quality control, and skilled craftsmanship to deliver custom-fabricated and welded solutions that meet the highest standards in performance and reliability.

From CAD to Part: The Process

Shenzhen Honyo Prototype: Custom Fabrication & Welding Production Process Guide

This section details the integrated workflow for transforming customer CAD data into precision custom fabricated and welded components, leveraging our CNC machining expertise as the foundation. Our process ensures manufacturability, cost efficiency, and adherence to stringent quality standards from initial inquiry through final inspection. The sequence is rigorously defined: AI-Powered Quoting, Design for Manufacturability (DFM) Analysis, and Controlled Production Execution.

The workflow commences with the AI-Powered Quoting Engine. Upon receipt of a validated CAD model (STEP, IGES, or native formats preferred), our proprietary AI system performs an initial geometric and material analysis. It automatically identifies key features relevant to both CNC machining and subsequent welding operations, such as complex contours requiring multi-axis milling, critical hole patterns for assembly, plate thicknesses, and potential weld joint geometries. This analysis generates a preliminary cost estimate and lead time within hours, significantly accelerating the RFQ cycle while providing immediate technical feedback on data readiness. The AI flags potential ambiguities, such as missing tolerances or incompatible material specifications, prompting early clarification.

This is immediately followed by a mandatory Engineering DFM Review conducted by our senior manufacturing engineers. This critical stage moves beyond automated analysis to apply deep practical knowledge of metal fabrication and welding processes. Engineers scrutinize the design for weld accessibility, optimal joint preparation (bevel angles, root gaps), material weldability, heat distortion control strategies, and the seamless integration of CNC-machined features with weldment assembly. Key considerations include minimizing weld passes, ensuring fixturing feasibility for both machining and welding stages, selecting appropriate filler metals, and verifying that tolerances are achievable post-weld heat treatment if required. Material selection is cross-referenced against our certified stock and welding procedure specifications (WPS). Customer collaboration is essential here; we provide actionable feedback for design optimization to reduce cost and lead time without compromising function.

Upon DFM sign-off and purchase order confirmation, Production Execution begins. CNC machining operations are prioritized to prepare all sub-components to precise dimensional specifications. This includes milling critical mounting surfaces, drilling/tapping holes for assembly, and cutting complex profiles using our multi-axis machining centers. Simultaneously, nesting software optimizes sheet metal cutting (laser, plasma, waterjet) for flat parts. Machined and cut components then proceed to dedicated welding cells. Welding is performed by certified technicians strictly adhering to approved WPS documents, utilizing processes matched to the material and joint requirements. Post-weld activities include stress relief (if specified), precision re-machining of critical surfaces affected by welding distortion, thorough cleaning, and comprehensive dimensional and non-destructive testing (NDT) per ASME or customer specifications. Final inspection validates all features against the original CAD model and quality requirements before shipment.

Material selection directly impacts weldability and process efficiency. Key parameters are summarized below:

| Material Type | Typical Thickness Range (mm) | Primary Weld Processes | Critical Considerations |

| :—————— | :————————— | :————————— | :—————————————— |

| Low Carbon Steel | 1.0 – 50.0 | MIG, FCAW, SMAW | Preheat for thick sections; control Zn coating |

| Stainless Steel 304 | 0.8 – 25.0 | TIG, MIG (Pulsed) | Minimize interpass temp; avoid carbon pickup |

| Aluminum 6061-T6 | 2.0 – 20.0 | TIG, MIG | Rigorous cleaning; high heat input control |

| Duplex Stainless | 3.0 – 40.0 | TIG (Root), SAW (Fill) | Strict interpass temp control; ferrite check |

This structured workflow, combining AI-driven efficiency with deep engineering expertise in CNC machining and welding, ensures Shenzhen Honyo Prototype delivers complex custom fabrications with reliability, precision, and optimal value for demanding industrial applications.

Start Your Project

Start Your Custom Fabrication and Welding Project with Precision Engineering

At Shenzhen Honyo Prototype, we specialize in delivering high-precision CNC machining solutions tailored to your custom fabrication and welding needs. Whether you’re developing prototypes for aerospace components, industrial machinery, or complex structural assemblies, our advanced manufacturing capabilities ensure your design is translated into a robust, high-performance part—on time and to exact specifications.

Our integrated approach combines state-of-the-art CNC machining with expert metal fabrication and welding services, allowing us to support projects from concept to completion. We work with a wide range of materials including aluminum alloys, stainless steel, carbon steel, and specialty metals, ensuring structural integrity and dimensional accuracy across both low-volume prototypes and medium-scale production runs.

What sets Honyo apart is our commitment to engineering collaboration. We don’t just manufacture parts—we partner with you to optimize designs for manufacturability, strength, and cost-efficiency. Our team of experienced manufacturing engineers reviews every drawing and 3D model to identify potential improvements in joint design, material selection, and welding methodology before production begins.

To ensure seamless integration of machined and fabricated components, we maintain tight tolerances throughout the process. Our CNC machining centers achieve precision down to ±0.005 mm, while our certified welders adhere to ISO 3834 and AWS D1.1 standards, supporting MIG, TIG, and spot welding techniques. Whether your project requires intricate frame assemblies or large-scale sheet metal fabrication, we combine automation with hands-on quality control to deliver consistent results.

Below are key specifications for our custom fabrication and welding services:

| Parameter | Capability |

|——————————|———————————————–|

| Material Types | Aluminum, Stainless Steel, Carbon Steel, Brass, Copper |

| Max Work Envelope | 3000 x 1500 x 800 mm (for welded assemblies) |

| Machining Tolerance | ±0.005 mm |

| Welding Standards | ISO 3834, AWS D1.1 |

| Welding Processes | MIG, TIG, Spot Welding |

| Surface Finishes | As-welded, Sandblasted, Powder Coating, Anodizing (Type II & III) |

| Lead Time (Typical) | 7–15 working days (depending on complexity) |

| Quality Inspection | CMM, Visual Inspection, Weld Penetrant Testing |

Every project begins with a technical consultation to align on design intent, performance requirements, and delivery timelines. We accept STEP, IGES, DWG, DXF, and PDF files and provide detailed feedback and DFM reports within 24 hours of submission.

Ready to bring your fabrication concept to life? Contact Susan Leo, our lead manufacturing coordinator, to start your project with confidence. With technical expertise, responsive service, and a focus on precision, Honyo Prototype is your trusted partner in advanced CNC machining and custom metal fabrication.

Email Susan Leo at info@hy-proto.com today to submit your design files, request a quote, or schedule a project review. Let’s build something exceptional—together.