Project Background
As high-end hospitality brands prioritize immersive guest experiences, a leading commercial display manufacturer launched a 2026 customization project for 1,500 units of round Android advertising displays, targeting luxury hotels, boutique resorts, and premium serviced apartments. Available in 18.5-inch and 23.8-inch sizes, these devices serve dual purposes: displaying dynamic hotel promotions, wayfinding, and event information when active, and functioning as decorative mirrors when powered off. The project required sheet metal enclosures that could meet strict aesthetic, functional, and environmental demands, with a focus on the unique circular form factor, mirror-grade surface finish, and durability in high-humidity hotel environments (e.g., bathrooms, lobby corridors).
Core Requirements Tailored to Round Hotel Advertising Displays
- Circular Precision: Dimensional tolerance ≤±0.05mm for the round enclosure, ensuring seamless alignment with the circular display panel and mirror substrate;
- Mirror-Grade Surface Finish: Flatness ≤0.1mm/m², scratch resistance (≥4H hardness), and uniform reflectivity to maintain mirror functionality when inactive;
- Water & Humidity Resistance: IP54 rating to withstand moisture in bathroom areas and occasional splashes, preventing corrosion and fogging;
- Structural Stability: Rigid frame to support the circular display and mirror, with vibration resistance for wall-mounted installation in high-traffic areas;
- Aesthetic Integration: Slim profile (≤12mm thickness) and seamless edge design to blend with luxury hotel decor;
- Modular Accessibility: Detachable rear panel for easy maintenance of internal Android components and wiring.
Sanjun Hardware was selected for its expertise in precision sheet metal for circular electronic devices, advanced surface treatment technology for mirror finishes, and ability to balance aesthetic refinement with functional performance—critical for displays that double as decorative mirrors in high-end hospitality settings.
Manufacturing Process of Core Sheet Metal Components
Sanjun focused on three core components: the circular front bezel (housing the display/mirror), the slim rear enclosure (for electronics), and the wall-mounted bracket. Production strictly followed ISO 10360-2 precision standards and hospitality-grade durability requirements.
1. Material Selection & Pre-treatment
- Front Bezel: 1.0mm 6061-T6 aluminum alloy—excellent machinability, lightweight, and compatible with anodized mirror finishing;
- Rear Enclosure: 0.8mm SPCC cold-rolled steel with galvanized coating—cost-effective, rigid, and corrosion-resistant for internal component protection;
- Wall Bracket: 1.2mm 304 stainless steel—rust-proof and load-bearing (supports up to 15kg) for secure installation;
- Pre-treatment: Automated degreasing + sandblasting + chromate conversion—removes surface impurities, improves coating adhesion, and ensures uniform mirror finish.
2. Core Manufacturing Craftsmanship
- Precision Laser Cutting: 5000W fiber laser cutting machine (±0.03mm tolerance) to cut the circular front bezel and rear enclosure, with a dust collection system to prevent surface contamination that could affect mirror reflectivity;
- CNC Bending & Forming: 7-axis CNC bending machine with custom circular jigs to form the slim profile of the front bezel, controlling springback within ≤0.04mm to ensure a tight, gap-free fit with the circular display panel;
- Mirror Surface Treatment: Two-step anodizing process (20μm thickness) + precision polishing to achieve a mirror-grade finish with 92% reflectivity, followed by a scratch-resistant topcoat (4H hardness) to maintain clarity in high-traffic hotel areas;
- Waterproof Sealing: Integrated silicone gaskets along the bezel-display interface and rear panel seams, paired with drainage grooves in the lower enclosure to prevent moisture buildup in humid environments;
- Assembly & Calibration: Automated alignment tools to ensure the circular display and mirror substrate are centered within the bezel, with a 100% visual inspection to verify no gaps or misalignment.
3. Quality Control & Testing
- Circular Precision Test: CMM inspection to confirm roundness tolerance ≤±0.05mm and concentricity with the display panel;
- Mirror Finish Test: Reflectivity measurement (≥90%) and scratch resistance test (4H pencil hardness) to ensure durability;
- IP54 Protection Test: Dust ingress and water splash testing per IEC 60529, verifying no moisture penetration into internal components;
- Structural Load Test: 15kg static load test for wall brackets, with no deformation or loosening;
- Environmental Durability Test: 1000-hour humidity cycling test (40%-80% RH) to confirm no corrosion or fogging of the mirror surface.
Project Challenges & Sanjun’s Solutions
1. Challenge: Maintaining Circular Precision & Concentricity
The circular form factor required ultra-tight tolerances to avoid gaps between the bezel and display, which would compromise both aesthetics and mirror functionality.
Solution: Used high-precision laser cutting and custom 3D jigs for bending, with real-time dimensional feedback from CMM inspection. Added locating pins to the bezel to ensure concentric alignment with the display panel, reducing misalignment rates to 0%.
2. Challenge: Achieving Mirror-Grade Finish Without Distortion
Traditional polishing processes often caused surface distortion, which would disrupt the mirror effect and display clarity.
Solution: Adopted a two-stage polishing process (mechanical polishing + chemical polishing) followed by anodizing, with a flatness inspection after each step. Used a vacuum clamping system during polishing to prevent warping, ensuring surface flatness ≤0.1mm/m².
3. Challenge: Waterproofing in Humid Hotel Environments
Bathroom installations exposed the enclosure to moisture and splashes, risking corrosion and fogging of the mirror surface.
Solution: Designed a drainage system in the lower bezel to channel water away from the display, paired with a breathable waterproof membrane to prevent fogging. Conducted 72-hour water splash tests to verify IP54 performance, with no moisture ingress detected.
4. Challenge: Batch Consistency for 1,500 Units
The project required uniform mirror finish and circular precision across 1,500 units, with no visible variation in reflectivity or alignment.
Solution: Implemented automated production lines for pre-treatment and surface finishing, with statistical process control (SPC) to monitor dimensional consistency. Each batch of 50 units was sampled for CMM and reflectivity testing, ensuring a 100% pass rate.
Project Outcomes
- Delivery Performance: 1,500 units (18.5-inch and 23.8-inch models) were delivered 5 days ahead of the 40-day deadline, with a 100% pass rate in all precision, finish, and durability tests;
- Market Feedback: After 7 months of deployment in 80+ luxury hotels, the displays received positive reviews for their seamless mirror functionality, aesthetic integration, and durability in humid environments. The client reported a 22% increase in display engagement from guests and a 15% reduction in maintenance requests;
- Long-Term Cooperation: The display manufacturer signed a 2-year strategic partnership with Sanjun Hardware, entrusting it with sheet metal customization for 3 new round display series (including 32-inch lobby models and waterproof bathroom variants). The client cited Sanjun’s “expertise in circular sheet metal precision and mirror surface technology” as the key driver of the partnership.
