Projekthintergrund
As e-commerce live streaming booms globally, a leading commercial live streaming equipment manufacturer launched a 2026 customization project for 1,200 units of e-commerce live streaming all-in-one machines, targeting professional live streamers, brand studios, and exhibition booths. The device features a circular upper section with a ring fill light and integrated camera, paired with a height-adjustable lower stand. The project required sheet metal components that could meet strict aesthetic, functional, and durability demands, with a focus on the unique roll-forming (not bending) process for the circular upper housing, the height-adjustable stand design, and the specialized sandblasting + anodizing finish for aluminum profiles.
Core Requirements Tailored to E-Commerce Live Streaming All-in-One Machines
- Circular Upper Housing: Roll-formed (no bending allowed) to ensure seamless, distortion-free roundness, with dimensional tolerance ≤±0.05mm for alignment with the ring fill light and camera module;
- Height-Adjustable Stand: Smooth vertical adjustment (range: 1200mm–1800mm) with stable locking, able to bear 25kg of equipment without wobbling;
- Specialized Surface Finish: Sandblasted + anodized aluminum profiles for a uniform matte texture, scratch resistance (≥5H hardness), and anti-fingerprint performance;
- Strukturelle Stabilität: Rigid upper housing to support the fill light and camera, with vibration resistance to avoid image blur during live streaming;
- Cable Management: Integrated hidden channels in the stand to organize power and data cables, ensuring a clean, professional appearance;
- Modulares Design: Detachable upper housing for easy maintenance of the camera and fill light components.
Sanjun Hardware was selected for its expertise in roll-forming precision sheet metal, advanced aluminum profile surface treatment, and ability to balance functional performance with aesthetic refinement—critical for live streaming equipment that demands both reliability and visual appeal.
Herstellungsprozess von Kernblechkomponenten
Sanjun focused on two core components: the circular upper housing (for the fill light and camera) and the height-adjustable lower stand. Production strictly followed ISO 9001 quality standards and live streaming equipment durability requirements.
1. Materialauswahl & Vorbehandlung
- Circular Upper Housing: 1.2mm 6063-T5 aluminum alloy—excellent ductility for roll-forming, lightweight, and compatible with sandblasting + anodizing;
- Height-Adjustable Stand: 6061-T6 aluminum profile (main support) + 1.0mm SPCC cold-rolled steel (locking mechanism)—high strength for load-bearing and smooth adjustment;
- Vorbehandlung: Automated degreasing + alkaline etching + neutralization—removes surface impurities and oxide layers, ensuring uniform adhesion of sandblasting and anodizing coatings.
2. Kern Fertigung Handwerk
- Roll-Forming for Circular Upper Housing: Used a 3-roller precision roll-forming machine (±0.03mm tolerance) to shape the aluminum alloy sheet into a seamless circular housing, eliminating the need for bending (which causes uneven stress and distortion). The process included real-time roundness monitoring with a laser gauge, ensuring consistent curvature across all units;
- Height-Adjustable Stand Fabrication: The main support profile was cut to length and machined with linear guide grooves, paired with a spring-loaded locking pin mechanism for smooth height adjustment. The stand base was laser-cut and bent to form a stable circular footprint, with reinforced welding at stress points;
- Specialized Sandblasting & Anodizing: The aluminum components underwent a 80-grit sandblasting process to create a uniform matte texture, followed by a hard anodizing treatment (25μm thickness) to achieve 5H scratch resistance and anti-fingerprint performance. The finish was tested for color consistency across batches to ensure visual uniformity;
- Kabelmanagement-Integration: Hidden cable channels were laser-cut into the stand profile, with rubber grommets installed to protect cables from abrasion during adjustment;
- Montage & Kalibrierung: Automated alignment tools ensured the camera module was centered within the circular housing, with a 100% functional test to verify smooth stand adjustment and stable locking.
3. Qualitätskontrolle & Testen
- Roll-Forming Precision Test: CMM inspection to confirm roundness tolerance ≤±0.05mm and no visible seams on the upper housing;
- Stand Stability Test: 25kg static load test for 24 hours, with no wobbling or locking failure during height adjustment cycles;
- Surface Finish Test: Cross-cut adhesion test (grade 5B) and scratch resistance test (5H pencil hardness) to verify durability;
- Vibration Resistance Test: 3G vibration test (50-500Hz) to ensure no camera blur or component loosening during live streaming;
- Umweltbeständigkeitsprüfung: 500-hour salt spray test to confirm corrosion resistance of the anodized finish.
Projektherausforderungen & Lösungen von Sanjun
1. Challenge: Achieving Seamless Roundness with Roll-Forming (No Bending)
Bending the aluminum sheet would cause uneven stress and visible seams, which would compromise the aesthetic and functional alignment of the ring fill light.
Lösung: Used a 3-roller roll-forming machine with custom tooling to gradually shape the sheet into a perfect circle, with real-time laser roundness monitoring. Added a post-roll polishing step to eliminate minor surface imperfections, ensuring a seamless, distortion-free finish.
2. Challenge: Ensuring Smooth, Stable Height Adjustment
The stand needed to support 25kg of equipment while maintaining smooth adjustment and secure locking, which required precise machining of the linear guide grooves and locking mechanism.
Lösung: Adopted CNC machining for the guide grooves (tolerance ≤±0.02mm) and used a spring-loaded locking pin with a detent mechanism to ensure stable positioning. Conducted 10,000 adjustment cycles to verify durability, with no signs of wear or loosening.
3. Challenge: Uniform Sandblasting & Anodizing Across Batches
Inconsistent sandblasting pressure or anodizing voltage would cause variation in texture and color, which would affect the visual uniformity of the equipment.
Lösung: Implemented automated sandblasting with pressure control (0.4–0.6MPa) and a constant-voltage anodizing system. Each batch of 50 units was sampled for texture and color inspection, ensuring a 100% pass rate for uniformity.
4. Challenge: Cable Management in the Adjustable Stand
Exposed cables would detract from the professional appearance of the equipment, and friction during adjustment could damage cables.
Lösung: Designed hidden cable channels with rounded edges and rubber grommets, paired with a strain relief system at the upper housing connection. Conducted cable pull tests to verify protection against abrasion, with no damage detected after 1,000 adjustment cycles.
Projektergebnisse
- Lieferleistung: 1,200 units were delivered 3 days ahead of the 35-day deadline, with a 100% pass rate in all precision, stability, and finish tests;
- Marktfeedback: After 6 months of deployment in 300+ live streaming studios and 50+ exhibition booths, the equipment received positive reviews for its seamless circular design, smooth height adjustment, and durable matte finish. The client reported a 28% increase in equipment sales due to improved user experience;
- Langfristige Zusammenarbeit: The live streaming equipment manufacturer signed a 3-year strategic partnership with Sanjun Hardware, entrusting it with sheet metal customization for 4 new series of live streaming devices, including portable models and dual-camera variants. The client cited Sanjun’s “expertise in roll-forming and specialized surface treatment” as the key driver of the partnership.
