We machine aluminum keyboard cases on 5-axis centers and anodize them in-house, so wall thickness, screw fit and color all come off one process chain.
Four failures we see on almost every incoming drawing.
Top and bottom shells anodized in two batches, or two suppliers, rarely match. The batch runs at a different temperature and dye concentration, so the seam between the halves is visible under office light. You rework or scrap the pair.
A 1.5 mm wall on a 6061 tray looks fine off the mill. The oxide layer grows inward and outward, and thin unsupported sections pull. Tolerances on the PCB pocket close up, and the plate no longer drops in without force.
M2 and M2.5 threads cut into soft aluminum, then anodized, lose thread depth to the oxide. The first assembly holds. The second torque cycle pulls the thread. That is a field return on a small run.
Bead blast before anodizing will not fix a bad stepover. Deep tool marks telegraph through clear anodizing because the coating is translucent. You see every pass on the top face, and the part is already coated.
One process chain from billet to sealed case.
A keyboard case is a pocket with four walls, a gasket groove, a USB cutout and a plate ledge. On a 3-axis machine that is four or five setups, and every refixture stacks error. We hold the body on 5-axis centers so the top face, the internal pocket and the side cutouts come from the same datum.
That matters most on the gasket groove and the plate ledge. If the groove depth varies around the perimeter, the gasket seal is uneven and the typing feel changes from left to right. One setup keeps those features concentric to the same reference.
Type II sulfuric anodizing builds roughly half its thickness into the aluminum and half outward. A 10 μm coating grows about 5 μm into the surface, so a threaded hole or a bearing bore changes size. We plan the pre-plate dimensions for that growth instead of discovering it after coating.
Color is a separate problem. Dye uptake depends on alloy, bath temperature, current density and how long the parts sit in the seal. When top and bottom shells must match, we run them in the same batch, on the same rack, with the same surface preparation.
Pick the alloy before you pick the finish.
| Alloy | Machined result | Anodized result |
|---|---|---|
| 6061-T6 | Stiff, clean threads, holds thin walls | Grey cast, consistent color, good hardcoat base |
| 6063 | Softer, easier on deep pockets | Brightest clear finish, best for bright colors |
| 6082 | Strong, good for large trays | Slightly darker clear than 6063 |
| 7075 | Highest strength, harder to machine thin | Anodizes unevenly, not for visible color |
| 5052 | Sheet metal cases only, not for billets | Good corrosion resistance, muted color |
One vendor for the metal, the finish and the marking.
Case bodies, weight bars and plates machined in one setup on 16 simultaneous 5-axis centers.
Clear, color, hardcoat and conductive anodizing, batch matched for multi-part cases.
Fine bead blast for a matte top face, or linear brushing for a directional look before coating.
Logos, layout legends and serial numbers engraved before or after anodizing. Minimum character height 1.5 mm.
Machined prototypes for fit checks against the PCB, plate and gasket before you commit to a run.
Thread inserts, gaskets and hardware fitted, then packed for shipment.
Numbers you can design to.
| Item | Range |
|---|---|
| Machining tolerance | ±0.005 mm (±0.0002 in) |
| As-machined finish | Ra 1.6–3.2 μm |
| Fine machined finish | Ra 0.2–0.8 μm |
| Maximum part size | 4,000 mm |
| Minimum wall thickness | 1.2 mm on supported sections |
| Anodizing types | Type II clear and color, Type III hardcoat, conductive |
| Color options | Clear, black, red, blue, grey, purple, orange, lime, green |
| Production start | Within 24 hours of drawing release |
Capability and process, not adjectives.
Fifteen years on aluminum parts, with 150 technicians across three wholly-owned plants.
16 five-axis, 12 four-axis, 27 three-axis and 16 mill-turn centers, plus a Ø400 mm rotary table.
Raw material check, in-process monitoring and final inspection on 100% of parts. Reports on request.
You get a price and a manufacturability review within 12 hours of sending files.
From a single prototype to a 10,000+ part run, same process chain and same inspection standard.
ISO 9001:2015, IATF 16949:2016, ISO 13485:2016 and ISO 27001:2022 certified.
Pocket and plate ledge held on one datum so switches sit flat across the row.
Groove depth controlled around the full perimeter for an even seal and even flex.
Long parts machined on 4,000 mm travel without tiling or joint lines.
6061-T6 is the default for a machined case. It holds thin walls, takes clean threads and anodizes to a consistent grey.
Choose 6063 if the case has deep pockets and you want the brightest clear finish or strong bright color. It is softer, so thread strength is lower and we usually recommend thread inserts for M2 hardware.
Type II coating grows about half into the aluminum and half outward. A 10 μm layer adds roughly 5 μm per coated surface.
That is 0.01 mm on a diameter that is coated on both sides. We compensate the pre-plate dimensions on bores and threads, but tell us which features are critical so the compensation goes to the right place.
Yes, if they run in the same batch on the same rack with the same surface preparation. Dye uptake is sensitive to alloy, bath temperature and current density.
If the two halves are made from different alloys, expect a visible difference even in the same bath. Keep one alloy across the whole case.
Ra 0.8–1.6 μm is a good general target for visible faces. As-machined at Ra 1.6–3.2 μm will show tool marks through clear anodizing because the coating is translucent.
Fine machining to Ra 0.2–0.8 μm gives the cleanest result on top faces. Bead blasting after machining hides small marks and gives a uniform matte look.
Yes. Uploads are secure and confidential, and we sign an NDA on request before you send files.
If the design is under embargo, send a simplified step file first for quoting and release the full model after the NDA is in place.
Yes. We machine single prototypes so you can check PCB fit, gasket compression and plate alignment before committing to a batch.
There is no minimum order quantity, so the prototype and the production run go through the same machines and the same inspection.
A 3D model in STEP or IGES, a 2D drawing for the critical dimensions, the alloy, the finish type and color, and the quantity.
No drawing yet? Send a sketch with the dimensions that matter and we will review manufacturability and come back with questions.
Standard packing is paper wrap, bubble bag, then carton. That is enough for most cases to arrive undamaged.
Heavy or high-value builds go into a wooden box. Shipping runs by DHL, UPS, TNT, FedEx, air or sea, and you can use your own forwarder.
Upload the model and drawing. You get a price, a DFM review and an anodizing note within 12 hours.
12-hour quote100% inspectionNo minimum order quantityNDA on request
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Upload your 3D model or 2D drawing and get a quotation with a free DFM analysis. Maximum processing size 4,000 mm.
CNC Metals 13 grades
CNC Plastics 10 grades
Machines & processes 12 options
Surface & post-processing 10 options
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