Create Your First Project
Start adding your projects to your portfolio. Click on "Manage Projects" to get started
Anodizing System
Project Type
Internal Operational Facility
Timeline
February 2025 - May 2025
Status
Completed; Capability of anodizing 9 parts (~ 300mm X 300mm X 25.4mm) in 24 hour cycle.
Roles & Responsibilities
1. Led the complete planning and development of an in-house Type II sulfuric acid anodizing (black dye) system to support internal manufacturing operations.
2. Defined and structured the full anodizing workflow, including degreasing, de-oxidizing, anodizing, dyeing, and sealing processes.
3. Studied and determined appropriate chemical compositions, solution proportions, and bath preparation methods to achieve consistent coating quality.
4. Engineered the anodizing tank configuration, including custom racking systems and fixtures to securely hold aluminum parts for uniform current distribution and coating thickness.
5. Conducted iterative testing to optimize electrolyte concentration, bath volume relative to tank size, and processing parameters for maximum efficiency and repeatability.
6. Coordinated with the electrical team to integrate a stable DC power supply system, ensuring proper current density control and operational safety.
7. Validated coating quality through visual inspection, surface finish evaluation, and durability assessment to meet internal and customer expectations.
8. Replaced paint-based surface finishing processes with anodized coatings, significantly improving corrosion resistance and product appearance.
9. Established operational procedures and handling guidelines to ensure safe chemical management and repeatable process execution.
10. Achieved production capability of anodizing up to nine aluminum components (300mm × 300mm × 25.4mm) within a 24-hour cycle.
11. Enhanced internal manufacturing capability by reducing time, increasing project output, and improving ability to urgent production requirements.
Technologies Used
1. Outsourced components: Caswell Anodizing Set-up System.
2. Materials: 6061 Aluminum
3. Testing: Different dimensioned aluminum parts, different mixture of electrolyte made with different chemical proportions, visual inspection, durability test, thickness and uniformity of coated layer test.
Key Highlights
- Designed and implemented an in-house anodizing (black dye) system to replace outsourced and paint-based finishing processes.
- Developed complete process flow starting from degreasing, de-oxidizing, anodizing, dyeing, and sealing with optimized chemical proportions and tank configurations.
- Engineered custom racking and fixture systems to ensure uniform coating quality and consistent current distribution.
- Conducted extensive process trials to determine optimal electrolyte concentration and operational parameters.
- Achieved production capacity of 9 aluminum components (300mm × 300mm × 25.4mm) per 24-hour cycle.
- Reduced turnaround time, improved surface durability and aesthetics, and enhanced customer confidence in product quality.
The Anodizing System project involved designing and implementing a small-scale, in-house Type II sulfuric acid anodizing (black dye) facility to support internal manufacturing. The goal was to reduce outsourcing dependency, shorten turnaround time, and improve product durability and appearance for major customers.
A complete process flow was established, including degreasing, de-oxidizing, anodizing, dyeing, and sealing, with dedicated tank setups and optimized chemical formulations. Custom racking and fixtures were engineered to ensure secure positioning and uniform coating quality, supported by extensive parameter testing. Integrated with a stable electrical supply, the system achieved a capacity of anodizing nine aluminum components (300mm × 300mm × 25.4mm) per 24-hour cycle. The implementation replaced paint-based finishes, enhancing corrosion resistance, surface quality, and overall manufacturing reliability.
