Feature Aluminum Alloy Shell (CNC Machined) 3D Printed Plastic Prototype Dimensional Accuracy ±0.001in tolerance, ISO 2768-mK compliant ±0.005–0.020in typical; prone to warping Material Representativeness Production-grade aluminum alloy (e.g., 6061-T6, 7075-T6) ABS, PLA, or resin — non-metallic, dissimilar properties Surface Finish…
Feature Aluminum Alloy Shell (CNC ±0.001in) Legacy Steel Housing Plastic Housing Tolerance Precision ±0.001 inches ±0.010 inches (typical) ±0.020+ inches (varies with molding) Weight Efficiency Lightweight; critical for EV range optimization Heavy; reduces vehicle efficiency Light but lacks structural rigidity…
Feature CNC-Machined Aluminum Alloy Shell (6061-T6) Conventional Cast Housing Manufacturing Tolerance ±0.001 inch ±0.005 inch or higher Material Grade Aerospace-grade 6061-T6 billet Cast aluminum or plastic composites Acoustic Resonance Control Eliminates resonance, reduces harmonic distortion by up to 17% Prone…
Property Aluminum 7075 Aluminum 6061 Advantage for Wearables Yield Strength ~503 MPa ~276 MPa 34% higher in 7075 — better crash/drop resistance Density 2.81 g/cm³ 2.70 g/cm³ Slightly heavier but offset by higher strength-to-weight ratio Thermal Stability Good up to…
Feature MIL-A-8625 Type II Anodize MIL-A-8625 Type III Anodize (Hardcoat) Coating Thickness 5–25 µm 25–100+ µm Surface Hardness 300–400 HV 400–700 HV Salt Spray Resistance 336–500 hours 1000+ hours Autoclave Cycle Tolerance ~200 cycles 500+ cycles Chemical Wipe Resistance Good…
Alloy Tensile Strength (MPa) Yield Strength (MPa) Elongation (%) Corrosion Resistance Machinability Cost Best Use Case in Automotive Interior 6061 310 276 12 Good Excellent $$ Trim panels, bezels, structural brackets 7075 572 503 11 Fair Good $$$ High-stress components:…
Feature Aluminum Alloy Shell (CNC Machined) Plastic Shell Tolerance Precision ±0.001in ±0.01in or less precise Heat Dissipation 3x faster than plastic Slower, prone to heat buildup Structural Rigidity Reduces key wobble, rigid chassis Flexible, may flex under use Durability (Actuations)…
Alloy Strength Weldability Corrosion Resistance Best Applications 6061 Medium-High Excellent Good Structural frames, automotive parts, marine fittings 6063 Medium Excellent Good Architectural extrusions, window frames, railings 7075 Very High Fair Fair Aerospace components, high-stress parts, tooling Anti-Fingerprint Coatings on Anodized…
Aluminum Alloy Thermal Conductivity (W/m·K) Thermal Resistance (Rθ) Target Regulatory Compliance (ESPR/IEC 62368-1) Typical Applications Machinability & Cost Predictability 6061 167 < 0.8°C/W achievable with CNC optimization Compliant with proper surface treatment and testing MacBook Pro chassis, consumer electronics Excellent…
Feature MIL-A-8625 Type II (Sulfuric Acid Anodizing) MIL-A-8625 Type III (Hardcoat Anodizing) Coating Thickness 5–25 µm 25–150 µm Corrosion Resistance (ASTM B117 Salt Spray) Up to 168 hours 336+ hours Wear & Abrasion Resistance Moderate High — suitable for high-stress…