A Real Customer Case Study: How We Precisely Delivered End-to-End Collaboration from Concept Design to Functional Validation
In the early stages of product development, transforming abstract concepts into reliable physical components is a critical step that often determines a project’s success or failure. Recently, Kaiao Precision partnered with a leading robotics technology company to support the development of key components for its next-generation collaborative robot. Through this real-world case, we demonstrate how Kaiao delivers professional, efficient services as a trusted R&D partner.
1. In-Depth Requirement Alignment: Defining What We Need to Build
At the start of the project, the client presented a challenging request: to produce multiple functional prototypes of a robotic end effector within a very tight timeline. These prototypes needed to meet several demanding requirements:
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High strength with lightweight design: Core structural components had to withstand loads and repeated impacts.
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High-precision assembly: Multiple components required tight tolerances to ensure smooth motion and reliable performance.
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Multi-material validation: The outer housing needed aesthetic quality and tactile comfort, while internal structures required different engineering plastic properties.
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Small-batch trial assembly: Multiple sets were required for full-system assembly testing and early market demonstrations.
Rather than moving straight to pricing, Kaiao’s sales and engineering teams conducted several rounds of in-depth technical discussions with the client’s R&D team. By analyzing product functionality, usage scenarios, and future mass-production plans, we jointly defined a phased, multi-process manufacturing strategy.
2. Customized Manufacturing Solution: Defining How We Deliver
Based on these discussions, the Kaiao team quickly delivered a comprehensive proposal covering process routes, material selection, lead times, and cost analysis:
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Core structural components
Manufactured via precision CNC machining, using 7075 aluminum alloy and POM (acetal). This combination ensured high strength, wear resistance, and precise dimensional control, enabling zero-error assembly of bearings and transmission components. -
Complex housings and protective covers
Produced using SLA rapid prototyping, allowing one-piece fabrication of complex surfaces and lightweight internal structures. After fine sanding and painting, the parts achieved an ABS-like appearance and surface quality. -
Flexible seals and small-batch replication
Manufactured through silicone vacuum casting. Based on the client’s 3D-printed masters, we quickly produced 10 sets of oil-resistant, flexible silicone sealing rings to support small-batch functional testing.
3. Efficient Collaboration and Transparent Project Management
Once the solution was approved, the project entered execution. Kaiao’s full-process transparent project management system played a key role:
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Dedicated project manager providing one-on-one coordination
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Progress updates at key milestones, including programming, first-article machining, and post-processing, shared via photos and videos
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Rapid response mechanism, enabling Kaiao’s engineering team to provide manufacturability and impact assessments within 2 hours whenever design adjustments were requested
4. Delivery and Value Beyond “Qualified Parts”
In the end, we not only delivered all components on schedule and fully compliant with specifications, but also provided added value through a detailed delivery report. This included:
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Identifying potential sink mark risks during future injection molding and recommending design optimizations
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Supplying surface treatment samples (such as anodizing options) for upcoming metal production parts
The client commented:
“The Kaiao team felt like an extension of our own R&D department. They didn’t just manufacture the parts—they thought ahead with us. This collaboration significantly reduced our tooling risks and accelerated the overall project timeline.”
Why Choose Kaiao Precision?
This case clearly highlights Kaiao’s core strengths:
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Technical experts, not just a contract manufacturer
We understand the deep connection between design and manufacturing. -
One-stop solutions
Seamlessly integrating CNC machining, 3D printing, and vacuum casting to deliver optimal solutions. -
End-to-end project management
Giving clients peace of mind so they can focus on innovation. -
A long-term partnership mindset
Our goal is to contribute to our customers’ product success through every collaboration.
We look forward to becoming the starting point of your next successful product.
Contact the Kaiao team today to receive your customized manufacturing solution.