The Collaborative Effort Behind a Complex Aluminum Die-Forged Part

2026-08-11

Achieving stable mass production of what appears to be a simple electric bicycle motor bracket is actually no easy feat.

This motor bracket is manufactured using an aluminum die-forging process, with two halves—left and right—welded together to form a single unit. The product consists of irregular curved surfaces, is hollow inside, and features a complex structure, while also demanding extremely high standards for dimensional accuracy and consistency.

For a product like this, the real challenge lies not merely in “producing the part,” but in controlling every quality risk.

From die design and billet cutting to rough forging, finish forging, trimming, and shaping—followed by parting line polishing, solution treatment, welding, machining, and finally X-ray inspection, dimensional inspection, and packaging—dozens of interlinked processes are involved, and every step can affect the final outcome.

During production, the key quality risks we face include: cracks, inclusions, indentations, material shortages, cold shuts, and—most critically—dimensional accuracy issues.

Particularly for these complex, irregularly shaped parts with wall thicknesses of around 6 mm, local thickness deviations must be controlled within 0.3 mm. This means it is difficult for any single department to resolve all issues on its own.

Therefore, we adopt a cross-departmental collaborative approach to problem-solving.

The engineering team starts with mold design, forging processes, and deformation control, continuously optimizing process parameters and workflow coordination;

The production team strictly adheres to process requirements, providing rapid feedback and making timely adjustments in response to issues that arise on the shop floor;

The quality team conducts end-to-end verification of critical dimensions and internal quality—from the first-piece inspection and in-process inspections to final inspection;

When issues arise, the technical, production, and quality teams jointly analyze the causes. Rather than simply handling a defective part, they identify the root cause of the problem and drive continuous process improvement.

The end result is more than just a complex process flowchart.

It embodies our engineering capabilities, production capabilities, and quality control capabilities when facing complex products.

From a complex product to a stable production process;

from identifying problems to solving them;

from a single successful run to sustained, stable mass production.

This is INNOVAW’s problem-solving and teamwork capabilities when tackling highly challenging aluminum die-forging projects.

We do not shy away from complex products; we fully commit to meeting stringent requirements.

We solve challenges with technology, bring solutions to life through production, and guarantee results through quality.