Metal Chassis Production Equipment

Complete Equipment Solutions for Metal Chassis Manufacturing

Metal chassis are the structural backbone of countless products: server racks, medical carts, industrial control consoles, audio amplifiers, test instruments, and electric vehicle battery trays. A high‑quality chassis demands precision-cut holes and slots, accurately bent flanges and rails, and robust welded joints.

ARCUS provides the complete equipment ecosystem to manufacture metal chassis in‑house. Our fiber laser cutters, CNC press brakes, and welding systems are engineered to handle mild steel, stainless steel, aluminum, and even galvanized materials – from thin‑gauge electronics chassis to heavy‑duty equipment frames. Contact us today to discuss which equipment configuration fits your chassis production volume and material requirements.

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Equipment Configurations for Common Chassis Types

Medical-Equipment-Chassis

Medical Cart / Mobile Chassis

Requirement: Stainless steel, #4 brushed finish, no heat tint Recommended Equipment: 4kW laser (nitrogen only) + 100 ton press brake + TIG welder

Industrial-Equipment-Chassis

Industrial Control Chassis

Requirement: Heavy‑duty mounting rails, large cutouts, welded corners Recommended Equipment: 4kW‑6kW laser + 150‑200 ton press brake + MIG welder

Electronic-Device-Chassis

Electronic / Control Cabinets

Requirement: Small enclosures, tight tolerances, EMI/RFI seam quality Recommended Equipment: 2kW‑3kW laser (precision thin sheet) + 50‑100 ton electric press brake

EV Battery Tray Chassis

EV Battery Tray Chassis

Requirement: Thick aluminum (¼″–½″), tight tolerances, high strength Recommended Equipment: 6kW‑8kW laser (anti‑reflection) + 200‑300 ton press brake + pulse MIG welder

Rackmount Chassis (1U–4U)

Industrial Control Chassis

Requirement: High accuracy, small vent patterns, tight bend radii Recommended Equipment: 2kW‑3kW laser + 50‑100 ton electric press brake

Computer-Chassis

Desktop / Instrument Chassis

Requirement: Clean edges, formed front bezels, EMI ground contacts Recommended Equipment: 3kW laser + 100‑100 ton press brake + TIG welder (optional)

The ARCUS Chassis Manufacturing Process

Learn Sheet Metal Fabrication

Step 1: Laser Cutting – Blank, Holes & Cutouts

Using an ARCUS fiber laser cutter, you cut the flat blank from sheet stock, including all mounting holes, card guide slots, ventilation perforations, I/O port cutouts, and cable pass‑throughs. Equipment: ARCUS Fiber Laser (2kW‑8kW depending on thickness) Key capabilities: ±0.003″ hole position accuracy (critical for card guides and mounting rails) Small hole cutting down to 0.040″ diameter Micro‑tab nesting to keep small chassis parts attached

Step 2: Deburring (Recommended)

Remove micro‑burrs from laser‑cut edges – especially important for chassis that handle printed circuit boards (burrs cause shorts) and for powder‑coated parts. Equipment: In‑line or standalone deburring machine (we can recommend integration)

Step 3: Bending – Forming the Chassis

Bend the flat blank into a 3D chassis shape: form the main U‑channel or box, bend front flanges, create EMI spring fingers, and fold side rails. Equipment: ARCUS CNC Press Brake (50‑200 tons) Key capabilities: ±0.5° bend angle accuracy – ensures flat mounting surfaces Multi‑axis backgauge for sequential bends (e.g., fold all four sides of a shallow chassis) Precision tooling for short flanges (as small as 0.25″)

Step 4: Welding (If Required)

For chassis that require closed corners, internal stiffeners, or attached brackets, weld the joints. Equipment: ARCUS TIG or MIG Welding System Key capabilities: Low‑heat input to prevent distortion on thin chassis panels Pulse control for spatter‑free stainless welds (visible on medical or cosmetic chassis) Programmable weld schedules for repeatable corner joints

Step 5: Finishing Preparation

While ARCUS does not perform finishing, our machines produce surfaces ready for powder coating, anodizing, or plating with minimal pre‑work. Nitrogen‑cut stainless edges have no oxide scale – ready for passivation.

Step 6: Assembly

Your team installs card guides, backplanes, hardware, and covers. Our machines produce parts with accurate hole locations – assembly is fast and predictable.

Recommended Equipment for Chassis Production

Fiber Laser Cutter – The Chassis Blanking Machine

ModelPowerMax Mild SteelMax StainlessBest For
ARCUS E Series2kW – 3kW½″ (12mm)¼″ (6mm)Thin electronics chassis, desktop chassis, prototypes
ARCUS Pro Series4kW – 6kW¾″ (20mm)⅜″ (10mm)Industrial chassis, medical carts, mid‑volume production
ARCUS Max Series6kW – 8kW1″ (25mm)½″ (12mm)Heavy‑duty EV battery trays, thick aluminum chassis

Key features for chassis:

  • High accuracy mode – fine‑tuned for small holes and slots (±0.001″ on hole diameter)

  • Nitrogen cutting for stainless – preserves corrosion resistance and brushed finish

  • Automatic nozzle changer – swap between nitrogen (clean edge) and oxygen (speed)

CNC Press Brake – Accurate Chassis Bending

ModelForceBending LengthBest For
ARCUS Electric50 tons5 feetHigh‑speed thin chassis (16ga–20ga), electronics, jit production
ARCUS B Series100 tons8 feetStandard rackmount chassis, instrument enclosures
ARCUS H Series150‑200 tons10‑12 feetLarge industrial chassis, EV tray frames, heavy‑duty

Key features for chassis:

  • Multi‑axis backgauge – handles complex sequences (e.g., bend rear flange then side flanges)

  • Quick tool change – change punch/die sets in under 5 minutes for different chassis designs

  • Crowning table – optional for long chassis panels (>36″) to ensure straight bends

Welding Systems (Optional)

SystemTypeBest For
ARCUS TIG 200PAC/DC TIGStainless steel chassis, aluminum chassis, cosmetic corner welds
ARCUS MIG 350Pulse MIGMild steel chassis, heavy‑duty frames, internal stiffeners
ARCUS Laser WeldingFiber laserHigh‑speed corner welding, low heat input, automation (high volume)

Key features for chassis:

  • Pulse control – minimizes spatter, eliminates post‑weld grinding on visible seams

  • Programmable schedules – one‑button for corner joints, rail attachments

Materials for Chassis – Machine Compatibility

ARCUS equipment is calibrated for all common chassis materials.

Material TypeCommon GradesLaser CutterPress BrakeWelderTypical Chassis Applications
Mild SteelA36, 1008, 1018Excellent (O2 or N2)ExcellentExcellent (MIG/TIG)Industrial control chassis, server racks, battery trays
Stainless Steel304, 316, #4 brushedExcellent (N2 only)Excellent (higher tonnage)Excellent (TIG)Medical carts, food service, cleanroom, outdoor
Aluminum5052, 6061Excellent (N2, anti‑reflection)Good (springback compensation)Good (AC TIG)Lightweight portable chassis, RF shields, EV trays
Galvanized SteelG90, A653Excellent (vented mode)ExcellentPoor (zinc fumes)Budget chassis, outdoor-rated enclosures

For galvanized, we include fume extraction recommendations. For stainless #4 brushed, our low‑pressure follower prevents scratches.

Our Service Commitment

We don’t just sell machines. We ensure your chassis production line stays running.

  • 24/7 North American Support – Real engineering support by phone, email, or remote desktop. Nights and weekends included.

  • 90‑Minute Response SLA – For critical issues (laser cutting head fault, press brake angle error), we respond within 90 minutes.

  • Free Lifetime Process Tuning – New chassis design or material thickness? We remotely dial in parameters at no charge.

  • US Spare Parts Warehouse – Nozzles, lenses, press brake tooling, welder consumables shipped same‑day from Chicago.

  • 3‑Year Limited Warranty – Covers laser source, press brake hydraulics, welder electronics.

  • Free Test Cut Before Purchase – Send your chassis drawing (DXF). We produce sample parts on ARCUS equipment and ship them back to you.

Typical Chassis Applications & Industry Examples

Ready to Equip Your Enclosure Production Line?

Whether you are a job shop adding new bending capacity or an OEM bringing bracket manufacturing in‑house, ARCUS has the laser, press brake, and welding systems you need.

  • Request a Quote – Tell us your typical bracket materials, thicknesses, and monthly volume.

  • Free Test Cut – Send a DXF. We produce sample brackets on ARCUS equipment and return them to you.

  • Live Demo – See a complete bracket production cell (laser + press brake) at our facility or via live stream.

Contact us today to start producing better brackets faster.

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    Frequently Asked Questions

    Q: What laser power do I need to cut 16ga (0.060″) steel chassis?

    A: 2kW cuts 16ga steel at >300 IPM – very fast. For occasional ⅛″ reinforcement, 3kW is more versatile.

    Q: How do I ensure card guide slots are perfectly aligned on both sides of a chassis?

    A: Use a laser cutter with high positional accuracy (±0.0008″) and nest corresponding slots together. ARCUS lasers include corner referencing for repeatable alignment.

    Q: Can I cut stainless steel chassis without heat tint on the edges?

    A: Yes – use nitrogen assist with optimized pulse parameters. ARCUS “medical grade” mode eliminates blue/yellow heat tint, even on #4 brushed surfaces.

    Q: What is the smallest flange I can bend on a chassis?

    A: With accurate tooling and a press brake with short‑depth stroke, we reliably bend flanges as short as 0.250″ (6.35mm).

    Q: Do you offer a complete chassis fabrication cell (laser + press brake + welder)?

    A: Yes. We provide fully integrated cells from flat sheet to welded chassis. Ask about turnkey packages with nesting software and automated material handling.

    Q: How do I get a free test cut of my chassis design?

    A: Send a DXF or STEP drawing. We cut, bend, and (if requested) weld sample parts on ARCUS equipment and ship them back. No obligation.

    Q: What training do you provide?

    A: Five days on‑site installation and training included. Remote refresher sessions available at no cost.

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