01
Wall thickness drifts after the first clamp
A 0.8 mm side wall looks fine on the CMM while held in the vise. Release the part and it springs 0.05 mm. The frame no longer seats flat against the display module, and assembly rejects the batch.
Precision CNC Machining
Aluminum Alloy Phone Frame CNC Machining
We machine aluminum alloy phone frames on 16 simultaneous 5-axis centers, holding ±0.005 mm across thin walls, camera bosses and antenna breaks. Prototype and production runs from one part upward.
±0.005 mm16 five-axis centersAnodizing in-houseNo MOQDFM in 12 hoursISO 9001:2015
16Simultaneous 5-axis centers
±0.005 mmAchievable tolerance
127CNC machines in three plants
3–5 daysTypical part shipping
Where phone frames fail
Four problems we see in aluminum frames
Each one traces back to a process decision made before the first cut.
02
Camera boss and speaker holes wander
Position error between the camera opening and the speaker slots shows up as a visible misalignment after anodizing. Rework means stripping the coating, re-cutting and re-anodizing, which costs several hours per frame and risks scrapping the part outright.
03
Tool marks show through the anodized surface
Anodizing does not hide cutter marks. Feed marks of Ra 1.6 μm or worse read as visible texture on a black hardcoat frame. The cosmetic spec fails even though the dimensions pass.
04
Quote and first article take too long
Your industrial design is frozen and the launch date is set. Waiting two weeks for a machined sample pushes the tooling review and the drop test into the same week, and every slip after that lands on the production schedule.
How we build it
One process chain for the aluminum alloy phone frame
From bar stock and DFM review to anodized, inspected frames in one shop.
Setup and clamping
5-axis machining in one setup, with soft jaws cut to the frame
A phone frame is a thin rectangular shell with a large open area in the middle. Clamp it the wrong way and the cutter pushes the wall away from the tool instead of cutting it. We rough the inside first, leave 0.3 mm of stock, then finish the outer profile on a 5-axis center so the frame stays supported by its own inner geometry.
Soft jaws are machined in place to match the frame's outer radius. That spreads clamping force across the full length of the side wall instead of concentrating it at two points. For a typical 6.1 in to 6.8 in frame, wall thickness stays within 0.05 mm around the perimeter, and the flatness of the display seating face holds at 0.03 mm.
The same setup reaches the camera boss, the speaker slots, the side button pockets and the antenna break grooves. Every feature that has to sit in a known relationship to the display datum is cut without re-fixturing, which is where most position error comes from.
- 1Rough then finish0.3 mm stock left for the finishing pass to control deflection.
- 2Soft jaws cut in placeClamping force spread along the full side wall.
- 3One datumDisplay face drives every other feature position.
Material and finish
Alloy choice and anodizing that survives a drop
We machine phone frames from 6061-T6 and 7075 most often. 6061-T6 gives good anodizing uniformity and enough stiffness for a frame with a 0.8 mm wall. 7075 offers higher strength for a thinner wall or a frame that has to pass a stricter bend test, but it anodizes with a slightly darker, less even tone, and it costs more per kilogram. If the cosmetic spec is tight and the structural load is moderate, 6061-T6 is the safer pick.
Anodizing is where a good machined frame can still fail. Type II clear or colored anodizing builds 5–15 μm and changes the outer dimension. Hardcoat builds 25–50 μm and changes it more, and it also builds into tight corner radii. We account for the coating thickness in the CAD model before cutting, so the finished frame meets the drawing after coating, not before.
Bead blasting before anodizing sets the surface texture. A uniform blast gives a matte finish that hides small machining marks. Polishing before clear anodizing gives a brighter surface but shows every scratch, so it only works when the machined finish is already Ra 0.8 μm or better.
- 16061-T6Uniform anodizing, good stiffness for 0.8 mm walls.
- 27075Higher strength, darker and less even coating tone.
- 3Coating allowanceType II and hardcoat thickness built into the model.
Material selection
Aluminum alloy for a phone frame: which one fits
Pick by wall thickness, structural test and cosmetic target.
| Alloy | Best for | Watch out for |
|---|---|---|
| 6061-T6 | 0.8–1.0 mm walls, uniform color | Lower yield strength than 7075 |
| 7075 | Walls under 0.8 mm, bend test | Darker, less even anodized tone |
| 6063 | Extruded-style profiles, bright clear coat | Softer, dents on impact |
| 2024 | High-strength structural frames | Poor corrosion resistance, needs coating |
| ADC12 | Die-cast bodies, not machined frames | Porosity shows after anodizing |
What we do
Services around the aluminum alloy phone frame
One shop for the frame, the fixtures and the finish.
01
5-Axis CNC Machining
16 simultaneous 5-axis centers cut the frame profile, camera boss and button pockets in one setup, holding ±0.005 mm on critical features.
02
Rapid Prototyping
Machined samples from bar stock so you can check fit, wall feel and drop behavior before committing to a production run.
03
CNC Milling & Turning
Milling for the frame shell, turning for round inserts, buttons and lens rings that share the same datum.
04
Surface Finishing
Bead blasting, brushing, polishing, Type II and hardcoat anodizing, laser marking for regulatory text and logos.
05
Sheet Metal Fabrication
Brackets, shields and internal carriers that mate with the machined frame at the same tolerances.
06
Die Casting and Vacuum Casting
For housing volumes where a fully machined frame is not the right cost choice, with machining on the critical faces.
Capability range
What we can hold on a frame
Figures are the shop's working limits, not marketing targets.
| Item | Range | Note |
|---|---|---|
| Tolerance | ±0.005 mm | Critical features, controlled conditions |
| Surface finish | Ra 0.2–0.8 μm | Fine finish for cosmetic faces |
| As-machined finish | Ra 1.6–3.2 μm | Typical non-cosmetic surfaces |
| Max part size | 4,000 mm | Larger frames and fixtures |
| Wall thickness | From 0.5 mm | With rough and finish passes |
| Order size | 1 to 10,000+ | No minimum order quantity |
Why GreatLight
Reasons engineers send us phone frame work
Data first, adjectives later.
15Y
Machining since 2011
Fifteen years of aluminum cutting, with the process sheets and fixture designs to show it.
±0.005
Tolerance we hold
0.005 mm on critical frame features, verified with reports on request.
16
Simultaneous 5-axis centers
Multi-face features cut without re-fixturing, so position error stays small.
127
CNC machines
Capacity to run prototypes and production in parallel across three plants.
3–5
Days to shipping
Parts ship in 3–5 days once the process is approved.
12 h
Quote and DFM turnaround
Quotation and free DFM analysis within 12 hours of receiving your files.
7,600 m²Manufacturing space
150Technicians
99.99%Qualification rate
<2%Historical late-delivery rate
Industry requirements
What these sectors demand, and what we hand over
Consumer electronics
Cosmetic faces must survive handling and coating without visible marks.
- Ra 0.8 μm finish
- Type II anodizing
Wearables and small devices
Frames thinner than a phone, where wall deflection is the main risk.
- 0.5 mm walls
- ±0.005 mm
Industrial handhelds
Rugged enclosures that need the same datum across frame and panels.
- 4,000 mm travel
- 100% inspection
Prototype to pilot build
Machined frames that feed drop tests and tooling review before mass production.
- 3–5 day shipping
- No MOQ
FAQs
Questions about aluminum alloy phone frame machining
Which aluminum alloy should I specify for a phone frame?
6061-T6 covers most frames with a 0.8 mm to 1.0 mm wall. It anodizes evenly and has enough stiffness for normal handling loads.
Choose 7075 when the wall goes below 0.8 mm or the frame has to pass a bend or drop test with a margin. Expect a slightly darker and less uniform anodized tone, and a higher material cost.
How do you keep a thin wall from deflecting during machining?
We rough the inner pocket first and leave about 0.3 mm of stock on the wall. The finishing pass removes that stock with light radial engagement, so cutting force stays low.
Soft jaws machined to the frame's outer radius support the wall along its full length. On a typical phone frame the wall thickness holds within 0.05 mm around the perimeter.
Does anodizing change the dimensions of the frame?
Yes. Type II anodizing adds roughly 5–15 μm per surface, and hardcoat adds 25–50 μm. These are not small numbers when the drawing calls out ±0.005 mm.
We build the coating thickness into the CAD model before cutting, so the finished part measures correctly after anodizing rather than before it.
What file formats do you need for a quote?
STEP and IGES are the most useful because we can check wall thickness and tool reach directly on the solid. Native CAD files also work.
Send a 2D drawing if you have one, especially for tolerances, datums and finish callouts. If the drawing and the model disagree, we will flag it during the DFM review instead of guessing.
Can you machine a frame from a single piece, or is assembly needed?
A single-piece frame is normal for phones and small devices. With 16 simultaneous 5-axis centers we reach the outer profile, the inner pocket, the camera boss and the side button pockets without re-fixturing.
Assembly becomes the better choice when the frame is long, when the internal structure is complex, or when a separate material is needed for a section such as an antenna window.
How many frames can you run, and how fast?
There is no minimum order quantity. We machine a single prototype and we run production lots past 10,000 pieces.
Quotation and free DFM analysis come back within 12 hours. Production can start within 24 hours of approval, and parts typically ship in 3–5 days.
What inspection data do you provide?
Every part is inspected before shipment, covering incoming material, in-process checks and final inspection.
Dimensional reports, material certificates and first article inspection reports are available on request. Tell us which features are critical and we will document those specifically.
How do you handle confidentiality?
Uploads are kept secure and confidential. We can sign your NDA, or provide our own through the non-disclosure agreement page.
If your program is unannounced, we restrict the files to the engineers working on the job and keep the part out of any public material.
Send your aluminum alloy phone frame for a quote
Upload a STEP file and get a quotation plus free DFM analysis within 12 hours. No minimum order quantity, and every part is inspected before it ships.
12-hour quote100% inspectionNo MOQNDA on request
