About Client
Industry: Robotic exoskeletons
Product: Aluminum Housing solution for custom robots
Location: California, USA
Why Xu Feng
Customer challenges: Quality issues and delays with previous suppliers; seeking to enhance the supply chain reliability
Xu Feng features: High-quality parts with competitive overseas pricing and smooth communication
Result: 3 types of 675 parts manufactured, leveraging CNC machining with multiple surface finishes, pin assembly and custom packing.
The Challenge of Client
Xu Feng recently crafted aluminum housing prototypes for a client in Poland specializing in rehabilitation equipments. During a discussion, EKSO, a leader in the field, noticed the exceptional quality of our parts and expressed keen interest. This positive exposure led to our introduction to EKSO, opening doors to new collaborative opportunities.
“Referring to the below correspondence between us, I would like to introduce you to persons from EKSO Company. They are interested in hip housings that you prepared for us.”
With previous suppliers, EKSO was faced with quality, cost, and speed tradeoffs, which affected their supply chain. When we were introduced to EKSO, a new director of operations joined their team.
“We have talked to some suppliers and provided by some offers,” said Charlie “For some, they had fast turnaround but very high prices, others had a little low price but their lead times were too long. and the previous local suppliers were more automated but couldn’t manage the specific details for tolerances or non-spec. surface finishes.”
Those issues didn’t only concern the parts that were unable to satisfy the client’s requirements but started to affect their supply chain and business.
Therefore, EKSO started looking for a partner who could address these pivotal supply chain issues that directly influence their bottom line. They need a reliable supplier that not only meets quality standards but also aligns with their operational timelines and cost expectations. This would enable them to swiftly fulfil orders and capitalize on new market opportunities.
The Solution from Xu Feng
The first thing We’d like to give you the basic knowledge of Robotic Exoskeletons
Understanding Robotic Exoskeletons
Robotic exoskeletons are advanced electromechanical suits designed to augment human physical capabilities or provide essential mobility assistance. These cutting-edge devices integrate sophisticated sensors, actuators, and mechanical structures, all governed by algorithms and control strategies that adapt to and enhance the wearer’s movements.
In the realm of robotic exoskeletons, precision and customization of components are critical. XuFeng specializes in providing customized mechanical components that meet these exacting standards, including custom-engineered aluminum housings. Our expertise ensures that each component not only meets the unique specifications required for effective performance but also enhances the overall functionality and efficiency of the exoskeleton.
Enhancing Robotic Engineering with Precision CNC Machining and Real-Time Collaboration
With over 20 years of specialization in customized CNC machining, Xu Feng’s dedication to continuous improvement and environmental sustainability has made us a leader in the industry. Our experienced engineers meticulously analyze each design drawing for optimization potential. For EKSO Robotics, this involved a thorough Design for Manufacturability (DFM) report, focusing on enhancing processing stability and incorporating eco-friendly practices.
Technical Adjustments for Optimal Performance
Our collaboration with EKSO Robotics led to significant technical enhancements:
- Updated Masking Requirements: Transitioned from partial to full-face coverage to enhance component protection.
- Finish Upgrades: Switched from Chemical Film Type I to Type II to incorporate eco-friendly practices.
- Structural Improvements: Added radius to the base of the main pocket to boost reliability.
The initial set of prototypes yielded excellent results, confirmed by Dan Rosenson, EKSO’s manufacturing engineer:
“I’ve finished the First Article Inspection (FAI). Both parts passed and look great. Absolutely no complaints. Very nicely done, Sunny.”
Streamlined Communication for Efficient Project Management
Charlie put us in a WhatsApp group, allowing for instantaneous updates and discussions on the project dynamics. This shift dramatically reduced response times concerning lead times and part statuses, facilitating rapid iterations and timely adjustments to meet project requirements.
“Typically, it took about a full day to hear back about lead times or the status of the parts, all due to the time difference overseas,” said Charlie. “Now, working with Xu Feng, we can get instant communication. It really helps us quickly iterate, talk through things on our parts that may need to change, and even get updates on parts and shipments.”
“It’s the right choice to work with Xu Feng because we know that they’re going to hit their lead times and we’re going to be in constant communication to see where our parts are in the production line.”
Delivering Precision in Complex Structures with Advanced Manufacturing Technology
Xu Feng’s commitment to excellence is vividly showcased in our handling of intricate structures demanding extremely tight tolerances. Our factory is equipped with state-of-the-art 5-axis CNC machines. This technology is pivotal in maintaining the integrity of complex designs, as it eliminates the need to transfer components across multiple fixtures, which makes it tough to hold tight tolerances.
Efficient Production and Innovative Tooling Solutions
Following the approval of the First Article Inspection (FAI), we successfully completed the bridge production in just 30 days. Then 3 new structures were provided in the next 2 months. Further enhancing our assembly process, we developed a new tool to facilitate seamless assemblies with flexible rotation capabilities. These advancements are testament to our proactive approach to addressing and optimizing manufacturing challenges.
Consistent Quality and Collaborative Improvements
Feedback from EKSO underscores the success of our projects:
- “The parts look great. They passed the incoming inspection and should be used on new devices shortly. Thank you for the good work,” confirmed the quality assurance team.
- “The FAI looks good and is approved,” remarked the engineering team.
- Our open dialogue for continuous improvement is also well-received: “Those are all good suggestions. We are actually redesigning the housing now to allow for more screw thread engagement.”
- Addressing even the smallest details, a manufacturing engineer noted, “I agree with the second point. I think the hole for the shoulder and the hole for the thread is slightly axially misaligned. This could cause the screw to slightly cross thread,” leading to immediate corrective action from our team.
“I’m especially happy to be able to communicate with Xu Feng at any time about design shortcomings and get good advice, which makes us feel like we’re working in the same team!”
Seamless Integration of Hardware and Software for Superior Results
Of course, the result comes from the interplay of hardware and software.
As I know there are many factories that also focus on CNC machining, but the problem is that our competitors don’t usually have 24/7 support as we do, and they also don’t want to spend time on new products which will cost a lot of time to communicate the progress of each step with clients in time. Now, you’ll know why we are a long-term cooperation partner and why we need you as our partner.
Xu Feng pays attention to every detail, including packaging and logistics. Because the parts are irregular shape and easy to collide with each other during transportation and risk injury, Xu Feng adopts cutting EPC to place the parts, which obviously shortens the time of unpacking and ensures the safety of the parts during transportation. In logistics, Xu Feng will also assist in preparing the customs clearance documents accurately, so that the time of transportation is greatly shortened!
Result
To date, the team has received 675, 4 different structure quality parts from Xu Feng, ranging from tight tolerance CNC machined parts with multiple surface finishes. Orders were matched with both domestic and overseas partners of EKSO and optimised for cost or speed based on their priorities.
In addition to quality and speed, Charlie said that the care and attention to detail that the Xu Feng team has demonstrated gives him confidence in a long- term partnership.
“From the beginning, Xu Feng really worked with us to understand our requirements.”
“At first sight, I chose Xu Feng because, from the first email, you could tell that they were approaching the relationship as a partner,” Charlie said. “Xu Feng was really working with us to understand what we need in terms of pricing, lead times, details of tolerances, and finishes, all tailored to the unique demands of our precision components.”
Charlie said Xu Feng was able to meet EKSO’s needs for specific types of manufacturing processes (such as precision CNC machining) and parts (such as aluminum housing and titanium connector). He added that XuFeng offers a dedicated team of manufacturing experts, which results in transparent pricing.
“All of the products we manufacture are relatively complex and we have very specific surface needs,” Charlie says. “For Robotic Exoskeletons, there are certain positions where tolerances are very important and unique, and XuFeng is very important in knowing where we are on the cost-quality tradeoff.”
Based on comparisons with previous suppliers, EKSO has saved approximately $300,000 after one year of working with XuFeng!
