1. Project overview
When a leading European industrial automation OEM needed to scale production of a new family of control cabinets with integrated cooling ducts and complex tube structures, they turned to TPS Elektronik. The client’s existing suppliers struggled with inconsistent bend radii, long lead times, and the need to coordinate multiple vendors for sheet metal enclosures, tube assemblies, and welding. TPS was engaged to provide a complete EMS sheet metal processing solution—from design feedback to finished assemblies.
By consolidating all metal processing under one roof, TPS eliminated the interface risks that previously caused rework and delays. This case study illustrates how integrated sheet metal processing can benefit system integrators and panel builders facing similar challenges.
For a comprehensive overview of TPS sheet metal capabilities, refer to our Custom Sheet Metal Fabrication guide.
2. The challenge: complex tube geometries and inconsistent quality
The client’s new control cabinet design required:
- Multiple stainless steel tubes with tight bend radii for integrated cooling channels.
- Complex 3D shapes that demanded precise cnc tube forming and repeatability.
- Welded assemblies with strict cosmetic and structural requirements.
- Enclosures with cutouts, threaded inserts, and powder coating that had to align perfectly with tube assemblies.
Initially, the client worked with separate suppliers: one for sheet metal enclosures, another for tube bending machine work, and a third for welding. This resulted in:
- Inconsistent bend angles and springback across batches.
- Long lead times due to coordination delays.
- Rework caused by mismatched interfaces between enclosures and tube assemblies.
- No single point of accountability for quality documentation.
As a result, the client faced extended project timelines and increased costs. They needed a partner with in-house cnc bending machine capabilities, welding expertise, and the ability to handle both sheet metal and tube processing under one quality system.
3. The solution: integrated EMS sheet metal & tube bending capabilities
TPS Elektronik proposed an integrated approach leveraging our full EMS sheet metal processing capabilities:
3.1 CNC tube bending & forming
We utilized modern cnc tube bender equipment capable of handling stainless steel and aluminum tubes with diameters from 10mm to 80mm. Our process included:
- Simulation of bend sequences to minimize scrap and validate tooling.
- Precision mandrel bending to prevent ovality and wrinkling.
- In-process dimensional checks using laser measurement.
This allowed us to achieve consistent bend radii within ±0.2 mm, meeting the client’s strict cooling channel requirements.
3.2 Sheet metal fabrication & welding
Simultaneously, we fabricated the sheet metal enclosures using laser cutting, CNC press brake forming, and automated welding. Welding processes were selected based on material and joint type:
- TIG welding for stainless steel tube-to-plate joints requiring high cosmetic finish.
- MIG welding for structural frame connections.
- Robotic welding for repeatable sub-assemblies.
For more on welding techniques, see our guides on MIG welding and MIG vs TIG welding.
3.3 DFM & quality integration
TPS provided DFM feedback during the design phase, helping the client optimize tube bend radii to use standard tooling and reduce costs. We also implemented a First Article Inspection (FAI) process covering both sheet metal and tube components to ensure interface compatibility before full production.
Learn how integrated sheet metal & tube bending can simplify your supply chain →
4. Project outcomes: precision, efficiency, and single‑source reliability
By consolidating sheet metal, tube bending, and welding with TPS Elektronik, the client achieved:
- Reduced lead time: 35% faster time from RFQ to finished assemblies compared to the previous multi‑vendor approach.
- Improved quality: Zero interface mismatches in the first production run; all tubes and enclosures mated perfectly.
- Lower total cost: Eliminated shipping between multiple suppliers and reduced rework.
- Full traceability: TPS provided a complete quality package including material certificates, weld inspection reports, and FAI.
The client’s engineering team noted that the DFM feedback on tube bend radii allowed them to simplify tooling and reduce per‑part cost without compromising thermal performance. The success of this project led to an ongoing partnership, with TPS now handling all sheet metal and tube processing for the client’s new product lines.
For system integrators and panel builders, this case illustrates the value of partnering with an EMS provider that offers true one‑stop metal processing. Explore our dedicated EMS Sheet Metal Processing for Electronics Enclosures page for more details.
