latest company case about Dongguan Kaiyan Hardware Products Co., Ltd. Certifications

Industry: Automotive Electronics / Autonomous Driving

Component: Two-Piece EMI Shielding Can (Frame & Lid)

Standard: IATF 16949 Certified Manufacturing

1. The Challenge: High-Frequency Interference & SMT Reliability

As New Energy Vehicles (NEVs) evolve toward L3/L4 Autonomous Driving, the complexity of RF modules (5G, V2X, Radar) increases exponentially. A leading Chinese NEV manufacturer approached us with three critical pain points for their ADAS Control Unit:

• Stringent Coplanarity: Due to the large PCB size, any warpage during Reflow Soldering would lead to pseudo-soldering. The required flatness was $< 0.08text{mm}$.

• Vibration Resistance: The vehicle environment demands that the Lid must remain securely attached to the Frame under constant high-G vibration (Grade 3 Road Load).

• EMI Integrity: Seamless shielding was required to prevent signal crosstalk in the $2.4text{GHz} - 6text{GHz}$ frequency bands.

2. Our Engineering Solution: Precision Engineering Meets Automotive Standards

Material Excellence: C7521 Nickel Silver

We selected $0.2text{mm}$ C7521 Nickel Silver for this two-piece structure.

• Why? It offers excellent solderability without post-plating (eliminating hydrogen embrittlement risks) and maintains superior oxidation resistance in harsh automotive environments.

Innovative Structural Design

• Advanced Dimple Locking: We engineered a proprietary multi-point "Dimple & Slot" locking mechanism. This ensures a high extraction force, preventing the Lid from detaching during vehicle operation while remaining manual-removable for maintenance.

• Pick-and-Place Bridge: The Frame features a removable vacuum bridge, optimized for high-speed SMT placement nozzles, maximizing production efficiency for the client.

• Stress-Relief Notches: Strategically placed corner notches reduce thermal stress during the reflow process, ensuring the Frame stays flat on the PCB.

Quality Control (Zero-Defect Goal)

• In-Line Laser Inspection: We utilized 3D laser profiling to monitor $100%$ of the production batch for coplanarity.

• IATF 16949 Workflow: Every coil of material and every batch of finished parts is fully traceable via our MES system.

3. The Results: Zero Failures in Mass Production

By partnering with us, the client achieved a seamless transition from prototype to high-volume manufacturing:

• SMT First-Pass Yield: Increased from $96.5%$ (previous supplier) to $99.92%$.

• Shielding Effectiveness: Verified at $> 55text{dB}$ across targeted frequency ranges.

• Lead Time: Initial T1 samples were delivered within 10 business days, supporting the client's aggressive vehicle launch timeline.

• Durability: Passed $1,000$ hours of High-Temperature/High-Humidity testing and random vibration tests without any structural degradation.

4. Technical Specifications for This Project