Expert Solutions for Machined Parts & Coating Area Estimation
At Ehisen, we combine a full in-house machining shop with a dedicated anode coating line to deliver custom titanium (and alloy) parts and precise coating area estimates for complex geometries. Whether your project involves electroplating fixtures, water-treatment assemblies, or hydrogen-electrolysis components, we machine to drawing, verify dimensions, and calculate effective coating area (including edges, holes, bends, and weld zones) for accurate loading and pricing. Our integrated workflow ensures tight tolerances, reliable lead times, and clear, data-backed quotations—so you get parts that fit, coatings that last, and costs you can trust.
Titanium Custom-Shaped Parts (CNC)
Five-axis machining with CMM checks for accuracy. We handle thin walls, internal bores, countersinks, precision threads, and sealing faces. On request, we include assembly datums and a clear coating-area breakdown (edges/holes/bends/welds) so your quote is precise.
Titanium Rings & Discs
Precision-turned/milled parts with thin-wall concentricity and runout under control. We 100% inspect OD/ID and end faces (CMM/gauges) and can provide a clear coating-area / masking breakdown for accurate quotes—shipped in export-ready, compliant packaging.
Titanium Fasteners
Standard-spec bolts, nuts, screws, and studs (ISO/DIN/ASME) in stock, with custom-to-drawing options for non-standard sizes. We support metric/imperial threads, Grade 2/5/7 materials, and inspection with CMM/gauges. Traceable lots and export-ready packaging.
Titanium Sputtering Targets
High-purity titanium targets for PVD sputtering—standard specs in stock, with custom shapes/sizes per drawing (planar/disc/rotatable). Options for purity (≥99.5–99.99%), grain control, back-side bonding, and Ra-controlled faces. Each lot is traceable, with COA and export-ready packaging.
principles of machining process
About Us
Why Choose Ehisen for Machined Parts & Coating Area Estimation?
At Ehisen, we combine a full precision machining shop with an anode coating line, making your parts dimensionally accurate, surface-clean, and coating-ready. From thin-wall features to miniature components, our process ensures the machined surface will support later sandblasting, pickling, and brush/spray coating without rework.
Extensive Machining Capability
Years of titanium machining with 5-axis CNC and CMM verification. We hold tight tolerances on bores, countersinks, precision threads, and sealing faces—even on very small parts—so assembly is right the first time.
In-Process Metrology for Precision
We control flatness, runout, Ra, and edge breaks during machining to prevent burr carryover and coating defects. Real-time checks keep surfaces consistent and ready for downstream treatment.
Integrated Coating-Area Estimation
We provide an auditable coating-area breakdown (edges/holes/bends/welds vs. masked zones) to align noble-metal loading and pricing with actual effective area—delivering accurate quotes and predictable performance.
Dr. Miao
Technical Director of Ehisen
Spencer Xu
CEO of Ehisen
Seamless Quote Integration
We link CAD-to-quote directly. Instead of guessing by outline, we calculate the effective coating area—including faces, edges, holes, bends, weld zones, and internal bores. The result ties area × loading (g/m²) to a clear price, preventing under- or over-quoting and keeping your budget on target.
Flexible Modeling for Complex Shapes
If no coating area is provided, we’ll create the drawings (2D/3D) from your model or sample and use software to compute the area by zones (coat vs. mask). For large or irregular parts, we segment the model for fast iteration and give a masking plan that aligns with your process and fixtures.
Verified Drawings & Auditable Reports
Our drafters prepare revision-controlled drawings; both sides confirm before production. You receive an area report (per zone), the loading plan (g/m²), and a price breakdown linked to each coated surface. Any change triggers a revised drawing and quote—traceable, consistent, and production-ready.
Why Coating Area & Surface Control Matter is Essential for Procurement Professionals？
For titanium anodes and machined parts, two factors decide cost and performance: accurate coating-area accounting and substrate surface control. At Ehisen, we convert your drawings/samples into CAD-based, zone-by-zone area (faces/edges/holes/bends/welds/bores) and link it to the loading (g/m²) and masking plan—so quotes are precise and comparable. Upstream, our 5-axis machining + CMM keep Ra, edge breaks, flatness, and burrs within coating-ready windows, improving wetting, adhesion, and lifetime. The result is accurate pricing, smoother schedules, and reliable field performance you can plan around.
Table of Contents
Chapter 1：Coating Quality Starts Upstream: Machining & Coating Collaboration
Coating-Ready Titanium Parts: Common Machining Issues & How to Avoid
Goal: Parts should go straight to blasting / pickling / brush-coating / sintering with no rework and no delay. Below are the problems that hurt coating the most—plus causes, how to prevent them, and how small pilot runs help.
1) Surface too shiny or too rough (Ra out of range)
Impact: Poor wetting and adhesion, uneven thickness, higher rework risk.
Common causes: Over-polish/grind, worn tools, wrong feeds/speeds/cooling.
Prevent:
Define Ra by zone on drawings (tighter on sealing bands, wider on general faces).
Unify edge breaks/chamfers to avoid sharp edges.
Run 2–5 pilot parts to lock tools and parameters.
2) Dimensional / GD&T errors (flatness, coaxiality, hole location)
Impact: Leaks and fit issues; after coating it’s much harder and slower to fix.
Prevent: Call out critical GD&T in the RFQ; do CMM checks on pilots; add supports for thin-wall parts to reduce re-clamps and heat distortion.
3) Burrs or flanges at hole/slot exits
Impact: Trapped chemistry, edge lift-off, pinholes.
Prevent: Deburr without smearing; add a small chamfer on exits; ask for close-up photos in pilot builds. If needed, add a light pre-blast to normalize surface energy.
4) Scratches / dents / fixture marks
Impact: Local thin coat, peeling, poor appearance.
Prevent: Film-protect key faces; use cushioned trays for transfers; mark no-touch areas in work instructions and confirm with pilot photos.
5) Sharp or inconsistent edges
Impact: Stress concentration → edge lift-off after coating.
Prevent: Specify a uniform edge break (e.g., 0.2–0.5 mm); compare edge photos during pilots and freeze the standard.
6) Thread problems (burrs, scale, short engagement)
Impact: Galling, hard to mask, damage risk.
Prevent: Require GO/NO-GO gauges and engagement length; agree mask/coat rules near threads; borescope deep features if needed.
7) Contamination / residue (oil, marker ink, abrasives)
Impact: Hard to clean in pre-treat; local coating failure.
Prevent: Use non-chlorine cleaners, white-glove handling; add cleaning checkpoints; do white-cloth / alcohol-swab tests before the furnace.
Summary Table ① — “Symptom → Cause → How to Prevent”
| Symptom / Issue | Typical Causes | Prevention (incl. pilots) |
|---|---|---|
| Ra too shiny or too rough | Over-polish, dull tools, bad parameters | Ra by zone, unified edge breaks; 2–5 pilots to lock settings |
| Flatness/hole/coax errors | Poor fixturing, heat warp | RFQ lists critical GD&T; CMM on pilots; thin-wall supports |
| Burrs at exits | Bad chip evacuation, wrong deburr | No-smear deburr; small chamfer; close-up photos |
| Scratches/fixture marks | Bare handling, hard contacts | Film + cushions; mark no-touch faces |
| Inconsistent chamfer/sharp edges | Mixed tools, hand variation | Uniform edge break (0.2–0.5 mm) with pilot photos |
| Thread defects | Tapping errors, chips left | GO/NO-GO, engagement length; thread masking rules |
| Contamination | Incomplete cleaning, chlorine use | Non-chlorine clean, white gloves; white-cloth/alcohol tests |
Pilot tip: Use pilots to align Ra/edge breaks, key GD&T, hole/threads, mask/coat zoning before volume. Stable production starts here.
Incoming Inspection & Fix Guide
Fast first, then decide. Break “big problems” into small measurable checks. You can finish incoming inspection in 10–15 minutes.
A. Quick incoming checks
Surface & Ra: Profilometer + low-angle light; white-cloth wipe should not leave black marks or mirror streaks.
Dims & GD&T: Look at the CMM summary (flatness / hole position / coaxiality); quick straightedge + feeler gauges.
Edges & exits: Magnifier + feel; check chamfer consistency.
Threads: GO/NO-GO gauges; borescope for deep features.
Cleanliness: Alcohol swab; compressed-air blow; no chlorine cleaner residue.
B. Remedies by severity
Minor (on-site fix): Light blast / fine polish to rebuild Ra; deburr / small chamfer; deep clean.
Moderate (rework): Local re-machining (face skim, ream/bore, re-tap); re-check CMM/Ra.
Severe (remake): Big flatness/hole errors, deep scratches, thin-wall warp → remake the part.
Summary Table ② — “Fix Level → Typical Actions → Time/Cost”
| Level | Typical Actions | Cost impact* | Lead-time impact* |
|---|---|---|---|
| Minor | Light blast/polish, deburr, deep clean | +1–3% | +0.5–1 day |
| Moderate | Local re-machining, re-tap, re-check CMM/Ra | +3–10% | +1–4 days |
| Remake | Make a new part (incl. scheduling) | ≈100% | +5–10 days |
* Reference ranges. Actuals depend on geometry, lot size, capacity, and any 3rd-party tests.
C. Contract tips (make it practical)
Put the minor / moderate / remake tiers into your PO or QA terms: who pays, how much delay is acceptable.
Define re-inspection evidence after fixes: CMM summary, close-ups, white-cloth test.
Freeze pilot acceptance items before volume: Ra by zone, edge photos, key GD&T, thread gauge pass, mask/coat map.
One-Stop Machining + Coating: Why Route Choices Decide Your Coating Quality
For titanium anodes (MMO titanium anode, platinum-coated titanium anode), machining decisions upstream directly shape current distribution, coating uniformity, and part stability in later brush-coating/electroplating and ≥400 °C thermal oxidation (sintering). Ehisen runs precision machining + anode lines under one roof, so we design for coatability from day one—fewer surprises, fewer reworks.
What Buyers Care About？
Coating evenness & lifetime on MMO (Ru-Ir / Ir-Ta) and Pt-coated titanium anodes
Current distribution in electroplating, EDI, chlorine evolution (CER), oxygen evolution (OER), cathodic protection
Deformation risks during brush coating → drying 100–200 °C → thermal oxidation ≥400 °C
Masking/fixture compatibility for complex geometries: plates, meshes, rings, tubes, baffles
A) Weld or Not? → Current Paths = Thickness Uniformity
Problem: Weld seams and repair zones change conductivity, creating hot spots/shadows in plating or brush coating → streaks, thin edges, uneven Ru-Ir/Ir-Ta/Pt.
Ehisen approach:
Compare one-piece machining vs. welded assembly for your geometry.
Adjust seam location or convert to mechanical joints when it helps current flow.
Use current guides/weighted coating and masking maps for edges/holes/bends/welds.
Quick compare
| Route | Pros | Risks for Coating | When we choose it |
|---|---|---|---|
| One-piece machining | Best conductivity; fewer interfaces | Higher machining time on complex parts | Precision parts, tight CER/OER uniformity |
| Welded assembly | Lower machining time; modular | Welds can cause hot spots/shadows | Large frames; we offset with seam design + current guides |
B) Residual Stress & Heat Input → Warping at ≥400 °C
Problem: Locked-in stress from roughing or heavy clamping twists thin walls during thermal oxidation (sintering).
Ehisen approach:
Add stress-relief between rough/finish; reduce re-clamps.
Use backing/supports for thin sections; verify flatness before coating.
Pilot 2–5pcs to check warp trend under real brush-coat + bake cycles.
Buyer tip: Ask suppliers to state where stress-relief happens and show flatness data pre- and post-bake.
C) Surface Texture & Edges → Adhesion and Lifetime
Problem: “Glassy” polish (too shiny), sharp edges, or flanged hole exits lower wetting → edge lift-off and early failure in MMO and Pt systems.
Ehisen approach:
Machine to coating-ready spec: Ra by zone (sealing bands vs. general faces), uniform edge break (0.2–0.5 mm), deburr without smearing.
Align with pickling / blasting / brush-coat windows so the surface activates predictably.
D) Datums & Process Sequence → Masking/Fixure Fit 
Problem: Machining datums that don’t match coating fixtures = masking gaps or exposed edges.
Ehisen approach:
Early datum + masking review with our coating team.
Add locating faces/hanging points on drawings; keep consistent through machining → coating → sintering.
E) How Ehisen Reduces Risk (Machining → Pre-treat → Coat → Sinter)
Integrated routing: we plan machining choices with CER/OER/EDI coating behavior in mind.
RFQ/design review: recommendations on weld vs. one-piece, stress-relief, Ra windows, edge breaks, and masking maps—before production.
Pilot first (2–5 pcs): verify current distribution, uniformity, and warp; tune weighted coating/current guides; freeze parameters for scale-up.
Traceable delivery: per-lot area breakdown (faces/edges/holes/bends/welds), loading targets (g/m²), and process records.
Plan the whole route at drawing sign-off
Positioning
For machined custom parts that will be brush-coated or electroplated as titanium anodes, don’t stop at “meeting dimensions.” At the drawing stage, plan the coating fixtures and masking together with machining: where to clamp, where to hang, how to mask, and in what orientation the part will go through drying and thermal oxidation. This keeps later steps smooth, repeatable, and low-rework while still meeting your dimensional and functional specs.A) Core principles
One datum, end-to-end: Keep machining datums aligned with coating fixture datums, so masking boundaries don’t “drift” and no seal bands or functional faces are over- or under-coated.
Define hang/hold early: Reserve hanging points / clamping faces in the model or drawing, away from critical coated areas; use softened/isolated contacts to avoid dents and marks.
Make boundaries visible: Turn coat / no-coat areas into clear, visible boundaries (incl. standard chamfer sizes and hole-edge rules) so operators can apply and inspect consistently.
Match orientation & flow: Choose the part orientation according to liquid/electrolyte flow and current paths during coating/plating; add current guides / weighted coats where needed to reduce hot spots and shadows.
Reusable & maintainable: Prefer fixtures/masks that are reusable, repeatable, and easy to clean, so they support takt time and future formula/part changes.
B) How to implement (from drawing to mass production)
Drawing confirmation
Mark in 2D/3D: coat / no-coat zones, chamfer ranges, hole-edge rules, hanging/clamping locations.
Provide a simple “masking & loading orientation” sketch that matches the machining datum scheme.
Trial fixtures & masks
Build trial fixtures/masks to verify locating accuracy and repeatability;
Choose materials that resist temperature/chemicals and allow quick change & cleaning.
Small pilot run (2–5 pcs)
Run the full chain: load → pre-treat → coat/plate → 100–200 °C dry → ≥400 °C thermal oxidation;
Record fixture photos, boundary close-ups, thickness uniformity, cycle time, and refine tools/steps.
Freeze for volume
Lock fixture ID, mask revision, loading orientation and key parameters;
Create incoming check points with photo specs to keep cross-lot consistency.
C) Deliverables & records (per lot, on request)
Masking/fixture/loading sketches (aligned with machining datums)
Zone boundary + chamfer/hole-edge rules (easy for on-site judgment)
Close-up photos (edges, hole exits, thread areas)
Cycle time & repeatability summary (optional)
D) Expected benefits
Smoother process: Faster loading, accurate locating, clear masking; fewer line stops and reworks.
More stable quality: More even thickness, no exposed edges, no edge lift-off.
Lower total cost: Reusable fixtures/masks, less precious-metal loss, steady takt.
Reliable delivery: One logic from drawing to mass production—better lot-to-lot consistency.
Chapter 2：Buyer Inputs, Reverse Engineering & Sample Validation
What we need from you (Machined Titanium Anodes)
1) The three most important items first:
Editable drawings or models — Use PDF to align views and dimensions; send STEP/IGES or DWG/DXF so we can calculate coating area and co-design masking/fixtures.
Coating boundaries — Tell us which areas must be coated and which must not. If the boundary crosses chamfers, hole edges, welds, or seal bands, please note how to handle them.
Operating conditions — Current density range (continuous/pulsed), medium and temperature (whether it has Cl⁻/F⁻/Br⁻/surfactants), target reaction (CER/OER/CP/EDI), and lifetime goal.
With these three, we can quickly plan the machining route, masking/fixtures, coating system, and a solid quote.
2) Dimensions, tolerances, and surface
- Please mark key dimensions and GD&T (flatness/position/coaxiality). It helps to give Ra by zone (tighter on seal bands, wider on general faces) and define a uniform edge break (e.g., 0.2–0.5 mm).
For threads, tell us the standard, engagement length, and whether they need masking or must conduct—this drives masking design and current paths. - Part orientation and loading
If you already prefer a loading/hanging way (e.g., “this face up for drying,” “use this hole as a hang point”), just say it. We will align machining datums with coating fixture datums so boundaries don’t “drift” later. - Labels and IDs
For production lots, labels/QR codes/batch or project numbers save time in receiving and assembly. If you have your own rules, we follow them. If not, we can propose a simple, practical scheme that fits your flow.
3) Only have a PDF or a sample? That’s okay
We can reverse-build 2D/3D from your PDF or sample, rebuild coating zones, identify mating materials, and compute coating area in software (faces/edges/holes/bends/welds).
Then we write a clear process sheet for “machining → pre-treat (blast/pickle curve) → brush coat + dry/sinter → final inspection,” and quote to that. You just confirm “yes/no,” we handle the rest.
4) Lead time and quantities
Tell us your sample count, target batch size, and the takt/lead-time window you hope for. This decides one-pass vs. staged fixturing, general vs. custom fixtures, and whether we need some time buffer for shipping steps later (detailed packaging/logistics will be on a separate page).
Inspection and acceptance scope
If you need a CMM report, Ra report, pinhole/spark threshold, AST settings, etc., we can lock them during process review. When “what counts as pass” is clear, the flow is smooth.
5) Two small but key notes
No exact coating area yet? Send us an editable model; we’ll measure and give a zone-by-zone area table as the basis for noble metal loading and pricing.
No fixed template? We can share a 1-page intake form (Ra/edge break/GD&T/masking/hang points/labels). Fill it and we can start review and samples.
NDA is supported. Your files are used only for engineering and production, tracked internally, and not shared.
You don’t need to send everything at once. Start with editable model + coating boundaries + operating conditions & lifetime. We’ll fill the rest during review. This makes the quote accurate, the schedule stable, and the first sample pass rate much higher.
If your info is incomplete—what we can do for you
Bottom line: Even if you only have a sample or a PDF, we can rebuild drawings, calculate coating area, define a repeatable process, quote clearly, and deliver a sample + data pack so you can move to volume with confidence.
A) From sample → drawings → manufacturable plan
We reconstruct 2D/3D (CMM/optical check; 3D scan if needed), align machining and coating datums, and identify whether the coating is MMO (Ru–Ir / Ir–Ta) or Pt.
We also identify fasteners and contact materials (XRF/spectro spot checks) to avoid galvanic issues.
Output: zone-by-zone coating area table (faces/edges/holes/bends/welds) as the anchor for noble metal loading (g/m²) and pricing.
B) Transparent process + quote (no surprises)
We write a clear process sheet + timeline and quote to it:
Machining: tooling, fixturing (one-pass vs staged), thin-wall supports, stress-relief nodes.
Pre-treat: blasting parameters / pickling curve; “no-use” chemicals (chlorine, silicone oils).
Coat + dry + sinter: per-pass wet film, dry 100–200 °C, ≥400 °C soak, forced cool to room temp; masking and hang points.
Final checks: CMM, Ra, pinhole/spark threshold, white-cloth wipe, edge/hole close-ups; (optional) area/load uniformity stats.
Your quote will show target loading (g/m²) & tolerance (e.g., ±10%), suggested ratios (Ru:Ir / Ir:Ta / Pt), any weighted coat/current guide, and whether fixtures are one-time.
C) Sample + data pack (prove it, then scale)
We ship samples with a compact data set so you can decide fast:
SEM (surface morphology), EDS (composition)
Thickness estimate (weighing / local cross-section)
AST (accelerated lifetime) window & hours (under agreed conditions)
Adhesion / bend (e.g., 180° bend, no visible flake)
Base Ra by zone + key close-ups
(Optional) polarization curve / comparison points
All files are linked to drawing rev / fixture ID / furnace number / station, so results are traceable.
D) Two ways to commit (price–lifetime logic)
| Commitment path | What you define | What we guarantee | When to use |
|---|---|---|---|
| Load-led | You fix noble metal loading (g/m²) | We guarantee loading accuracy (and tolerance) | You must match a legacy spec or cost cap |
| Performance-led | You define lifetime window & conditions | We propose formula + process and stand behind lifetime | You want the best cost-to-life ratio |
Short version: You fix grams → we guarantee grams. You fix life → we guarantee life.
E) Precious metal price locking (simple and fair)
Metal moves daily. We offer three lock points—pick one to match your finance process:
| Lock basis | How it works | Typical use |
|---|---|---|
| Order date | Price fixed on PO date | Fast decisions, stable budget |
| Payment date | Price fixed when funds clear | Suits prepay workflows |
| Shipment date | Price fixed at dispatch | Suits long NRE/fixture lead-ins |
If lead time slips for reasons beyond control, we’ll align on a small adjustment band up front to keep it predictable.
F) Third-party testing & customer standards
Need an outside lab? We can coordinate third-party tests to your method (AST conditions, pinhole/spark, cross-section, XRD/XPS, etc.) and include official reports in the data pack.
G) Old-anode take-back (optional, value add)
We can weigh and strip old anodes to estimate remaining value—use it for credit or benchmarking against the new design. This often helps trim your total cost of ownership.
H) A realistic timeline (example)
T0 — Receive sample/PDF → 3–5 workdays: reverse drawings + area table
T1 — Process review + quote sign-off → 1–2 workdays
T2 — Sample build + data pack → 7–15 workdays (multi-pass coat + sinter cadence)
T3 — Freeze + ramp → depends on batch size and fixture type (we’ll show both one-time and general fixture options)
Why this works for buyers: you get a clear plan, proof by data, and clean commitments (either grams or life). That’s how you control cost, schedule, and risk—before volume.
Samples + Feedback = Certainty
Core idea
Start with a small pilot (2–5 pcs) to answer three things: Can it work? Is it stable? What does it cost?
In the sample phase, we make the coating area, loading (g/m²), masking/fixtures, and cycle time measurable. Just as important: the first parameters you share are often theoretical. We need real operating data from your site (current density, temperature, pH, on/off pattern, chemical top-ups) to feed back into the recipe and process so the result matches reality and is repeatable.
A) Change one variable at a time: small steps, quick learn, clean scale-up (2–5 samples)
Like R&D, we change one process factor at a time so conclusions are clear and reliable.
Example path
Fix coating formula & g/m² → compare only blast mesh (#180 vs #240).
Fix blasting → compare pickling mix/time window; check adhesion & white-cloth test.
Fix the above → check with/without welding impact on current paths & thickness; add current guides / weighted coats if needed.
Fine-tune drying 100–200 °C and soak ≥400 °C for 10–15 min; verify warp trend & lifetime window.
What you receive with samples (the “data pack”)
SEM/EDS, thickness estimate (weighing / local cross-section)
AST hours (under agreed conditions)
Adhesion/bend (e.g., 180° bend, no visible flake)
Ra by zone, key close-ups (edges/holes)
Passed items are frozen into a Mass-Production Parameter Sheet (drawing rev, mask rev, fixture ID, load orientation/station, process window), plus your real operating data—so everything is traceable.
B) Make cost drivers visible (what moves your price)
| Driver | What matters | How to control it |
|---|---|---|
| Coating area | Faces/edges/holes/bends/welds effective area | 3D area table by zone → price anchor |
| Loading (g/m²) | Target & tolerance (e.g., ±10%) | Calibrate in samples; then lock tolerance; spot-check weight/strip in mass |
| Pass count & cycle | Wet-film limit, dry/soak time | Use samples to set upper limits, avoid extra passes |
| Masking/fixtures | One-off vs reusable | Design quick-change, reusable tools to spread cost |
| Inspection scope | CMM, Ra, pinhole/spark, AST | Focus on items that really affect life/assembly |
| Metal price | Lock rule & period | See annual lock with a small adjust band |
| Real vs theory | Site data differs from plan | Log deviations in samples and feed back to process |
C) Two commitment paths: you fix grams or you fix life
| Path | You define | We guarantee | When to use |
|---|---|---|---|
| Load-led | Fixed g/m² | Loading accuracy (with tolerance) | Match legacy spec or hard cost cap |
| Performance-led | Lifetime window & conditions | We define formula + process and guarantee lifetime | Optimize cost-to-life outcome |
In short: You fix grams → we guarantee grams. You fix life → we guarantee life.
D) Annual precious-metal lock: set after samples—more stable, less stress
After samples/small batch pass, set an annual (or rolling quarterly) volume and lock a base metal price range.
If market drops beyond a small threshold (e.g., ≥3%), price moves down.
If market rises (within the agreed band), your unit cost doesn’t go up.
Goal: isolate price swings from your cost so budgets and quotes stay steady.
Contract can name: index & period, drop threshold, rise “no-increase” band, minimum volume, monthly reconciliation with screenshots.
E) Third-party testing & old-anode buy-back (optional value)
Third-party / your standards: We can coordinate outside labs (AST, cross-section, XRD/XPS, pinhole/spark, etc.) and include official reports.
Old anode recovery: Weigh & strip to estimate residual value for credit or benchmarking, cutting your total cost of ownership.
F) Milestones & timing (example)
T0 — Receive sample/PDF → 3–5 workdays: reverse drawings + zone area table
T1 — Process review + quote sign-off → 1–2 workdays
T2 — Sample build + data pack → 7–15 workdays (multi-pass coat + sinter cadence)
T3 — Freeze & ramp → depends on batch size and fixture plan (we offer both one-time and general fixture options)
G) When you save the most (and cut risk)
Send an editable model (STEP/DWG) → exact area → no excess metal.
Use samples to settle orientation / current guides / weighted coats → fix uneven thickness before mass.
Keep inspection focused on key items → enough data to decide, without over-cost.
Reusable masking/fixtures → spreads cost over many batches.
Feed real site data back → avoid “built to theory, fails in reality.”
Summary
Theory is the starting map; samples + real feedback are the road. With one-variable-at-a-time trials, a clear grams-or-life commitment, and annual metal lock, you control cost and lifetime. Add reusable tooling and right-sized inspection, and you get a machined titanium anode program that is high-value, stable in delivery, and fully traceable.
Chapter 3：How do I ensure accurate coating area and stable quality for titanium anodes?
Why choose a supplier that can both machine and CAD?
In titanium anodes, the “effective coating area” is not a fixed number. It sets your current density, cell voltage, and coating/electroplating time, and it also determines precious metal usage (g/㎡) and lifetime window.
If a supplier only reads a 2D drawing and roughly estimates area, you’ll likely see: parameter drift → uneven thickness → rework & delays → higher total cost. We recommend one supplier that does machining + CAD together to remove errors at the source.
1) Which key items does area affect?
Price: Precious metal is calculated by g/㎡. The more accurate the area, the more accurate the budget. Too large = overpay; too small = extra plating/recoat later.
Process: Current, voltage, and time for electroplating/brush coating are set by the effective area. If area is wrong, the process settings will be wrong.
Lifetime: Uneven thickness, edge exposure, and hole-rim issues often come from not aligning area rules + masking/fixtures + part orientation in advance.
Quick formula (easy for internal use):
Area (㎡) × Target loading (g/㎡) → Total precious metal (g) → Current & takt → Thickness/Lifetime consistency
2) Why does “machining + CAD” fix it from the start?
Machining creates the real geometry (chamfers, holes, bends, weld zones).
CAD/3D modeling turns that geometry into measurable 3D zones (faces/edges/holes/bends/welds) and co-designs with masking/fixtures/orientation.
Together, they align the process inputs before sampling, so you don’t rely on rework later.
Our usual steps:
2D → 3D modeling: Convert 2D to 3D; mark coat/no-coat borders and how to handle chamfers and holes.
Zoned area calculation: Split faces/edges/holes/bends/welds and output a zoned area table (the anchor for price and g/㎡).
Orientation & fixtures: Align machining datums with coating fixtures; plan drainage and weighted coats to reduce uneven thickness.
Closed loop: Area → loading (g/㎡) → current density/time → QC items (CMM, Ra, pinhole/spark…) become a process sheet. After samples pass, we freeze mass-production parameters.
3) Visible differences (two quick snapshots, as support—not the main point)
Electroplating set by area: If effective area is off by 10%, current setpoint can be off ~10%—leading to over/under-plating, higher energy use, and lifetime swing.
2 mm perforated plate pricing: If priced by full sheet area, buyers overpay. After 2D→3D and precise zoning, the effective area is clearly smaller than the sheet. You may not feel it in samples, but in mass orders the gap adds up to real cost.
Value of “machining + CAD”: connect real geometry → measurable area → executable process, so price and lifetime are both under control.
4) A quick supplier self-checklist you can use
Can they provide a 3D zoned area table (faces/edges/holes/bends/welds) instead of a rough full-sheet estimate?
Are machining datums and coating fixtures on the same datum? Is part orientation/hanging point decided upfront?
Does the quote state target g/㎡ and tolerance, and show how current/time are derived?
After samples pass, do they issue a Mass Production Parameter Sheet bound to drawing REV/fixture/furnace for traceability?
5) What you get when working with Ehisen
Zoned area table (3D based): clear anchors for pricing and loading.
Process sheet: machining → pre-treatment (blasting/acid pickling curve) → coating/dry/sinter (incl. ≥ 400 °C soak & forced cooling) → QC route.
Sample data pack: SEM/EDS, thickness estimate, AST hours, zoned Ra, border close-ups.
Mass-production freeze: drawing REV, masking version, fixture ID, orientation/station, QC thresholds—all locked.
Annual metal lock (optional): after sample/pilot success, lock a yearly precious-metal basis—pass on decreases, don’t pass on increases (within the agreed window).
In one line: When machining and CAD live in the same loop, area is accurate, process settings are stable, and both lifetime and cost stay controlled. This is the most important—yet often overlooked—factor when you choose a supplier.
From 2D to 3D: align real, manufacturable geometry with quoting and process
Bottom line first: A 2D drawing only gives a rough area estimate. Converting 2D to a 3D model and doing zoned area calculation (faces / edges / holes / bends / weld zones) lets your quote (g/㎡ × area) and process settings (current / voltage / time) match the real geometry. That’s how you get repeatable thickness and lifetime—and keep cost and lead time under control.
1) Why 3D is a must
2D misses details: It can’t fully capture chamfers, rounded edges, hole rims, bend transitions, weld toes/overfill—all of which change the effective coated area.
Parameter drift: Current density (A/㎡) and takt time (min/pass) are set by area. If area is off by 5–10%, I/V/t shifts too → uneven thickness, over/under-plating.
Cost errors: Precious metal is by g/㎡. Small errors in samples become real cost when scaled to mass production.
In short: Without a 3D zoned area table, all later settings only “look reasonable.”
2) Our approach: turn drawings into a model that’s calculable, buildable, and traceable
Fast workflow
| Step | What we do | Output | Why it matters |
|---|---|---|---|
| 1. Drawing intake | Check dimensions, tolerances, coat/no-coat marks | 2D check list | One set of rules, no misunderstandings |
| 2. 2D → 3D modeling | Build chamfers/fillets, hole steps, bend transitions, weld geometry | Editable 3D model (STEP/DWG) | Shows real geometry |
| 3. Zoning & area | Split faces/edges/holes/bends/welds; calculate each zone | Zoned area table | Anchor for quote & g/㎡ |
| 4. Orientation & fixtures | Set part orientation/hangers, masking borders, drainage/weighted coats | Fixture/masking sketch (linked to 3D) | Stable borders, smoother thickness |
| 5. Process loop | Derive area → loading (g/㎡) → I/V/t | Process sheet (incl. dry/soak/cool) | Repeatable thickness & lifetime |
| 6. Freeze & trace | After sample pass, lock REV / fixture ID / furnace | Mass-production parameter sheet | One-to-one with QC & quote |
3) 2D rough estimate vs 3D zoned calculation (clear differences)
| Topic | 2D rough (common) | 3D zoned (our way) |
|---|---|---|
| Hole arrays / rims / chamfers | Often ignored or averaged | Hole rims, walls, chamfers as separate zones |
| Bends & transitions | Uses flat “developed” area | Inner/outer arcs zoned; handles build-up/low-thickness risks |
| Weld zones | Counted as “flat” | Toe/overfill/HAZ split with their own rules |
| Quote accuracy | OK in samples, drifts in mass | Matches real build; quote is explainable |
| Process mapping | I/V/t easy to mis-set | Area → g/㎡ → I/V/t maps 1:1 |
| Traceability | Hard to review | Area table + REV + fixture + furnace trace together |
4) Embedded example (kept short): Ø2 mm perforated plate
If you price by full sheet area, buyers often overpay.
After 2D→3D, we include hole rims, wall edges, chamfers in the rule. The effective coating area is clearly smaller than the sheet.
Impact: Not obvious in samples, but in mass orders the gap adds up (higher precious-metal cost). Also I/V/t shifts and thickness varies.
With a 3D zoned area table, these “detail areas” are quantified and fixed—so quote, process, and QC finally speak the same language.
5) How it ties to process & QC
Process: Set current density / cell voltage / time by the zoned area. For hole rims, bends, welds, define weighted coats / drain aids / masking borders.
Cycle: Define wet-film limit per pass, 100–200 °C drying, ≥ 400 °C soak, forced cool to room temperature; set pass count.
QC: CMM (critical GD&T), zoned Ra, pinhole/spark thresholds, white-cloth wipe, and when needed AST window & hours—all bound to drawing REV / fixture ID / furnace.
6) A quick acceptance checklist you can use now
| Item | What we provide | Your benefit |
|---|---|---|
| Zoned area table | Face/edge/hole/bend/weld data by zone | Clear quote anchor, no overpay |
| 3D-linked masking/fixture sketch | Orientation/hangers/borders on one view | More uniform thickness, fewer reworks |
| Process sheet | Area → g/㎡ → I/V/t closed loop | Copyable settings, predictable cycle |
| Mass-prod parameter sheet | Bound to REV/fixture/furnace | Traceable QC & delivery |
Summary
Turn 2D into 3D and calculate every border by zone. That’s the only reliable way to align Quote — g/㎡ — I/V/t — QC with real geometry. The payoff: more accurate pricing, steadier process, repeatable lifetime—and a budget and lead time you can truly control.
How to coat and inspect complex shapes？
In one line for buyers:
For complex parts (dense small holes, long/deep slots, chamfers, welds, bends), you must decide in one 3D model how to count area, set borders, choose part orientation, and design masking/fixtures. If not, you’ll get uneven thickness, under-plating at hole rims, edge exposure, or peeling at welds. These issues hit what you care about most: price (precious-metal grams), lifetime (AST), and lead time (rework).
Applies to: MMO titanium anode, platinum coated titanium anode, titanium mesh anode, titanium plate anode for electroplating, cathodic protection anode (SEO keywords included).
1) How we make complex shapes clear and stable
One 3D view for everything: In the CAD model we name zones for faces / edges / holes / bends / welds, then export a zoned area table. Quotes and target g/㎡ now share one anchor.
Fix orientation before production: Part orientation decides current flow and drying/solvent paths (e.g., whether hole rims go thin or slot bottoms go thin). We try small samples first, then freeze the best orientation in the process sheet.
Masking + fixtures decided together: Masking borders follow the 3D zone borders. Fixtures align to machining datums; hang points/supports are confirmed early so borders don’t “drift” later.
Weighted coats for weak zones: For hole rims, outer arcs, slot bottoms, we set weighted coats / drain aids to reduce rework.
2) What buyers care about — quick table
| Typical area | Common issue | What we do | Your benefit |
|---|---|---|---|
| Small hole arrays (e.g., Ø2 mm) | Under-plating at rims, edge marks | Make a separate hole-rim zone in 3D; set weighted coats + drain aids; separate spark-test threshold | More uniform thickness, higher pass rate, fewer reworks |
| Long/deep slots | Thin at the bottom, bubble trapping | Prefer slot-up orientation; control wet film per pass; guide hot-air flow | Fewer wasted passes, predictable takt time |
| Chamfers & sealing bands | Edge exposure, runs | Zone chamfers; use two-step masking; link Ra with chamfer size | Better sealing and consistent appearance |
| Welds / HAZ | Local peeling, pinholes | Split toe/overfill; set special pre-treat and spark threshold | Stronger weld zones, lower repair risk |
| Bends (inner/outer arcs) | Build-up inside, thin on outer arc; orange peel/runs | Separate inner/outer arc zones; weight outer arc; tune orientation and air flow | Tighter thickness distribution, stable look |
3) Quick examples (to judge if you need 3D zoning)
Plates with many holes (e.g., Ø2 mm): Quoting by full sheet area usually means overpaying precious metal. With 3D zoning, the effective coated area is more realistic, so both the quote and current settings are more accurate.
Plates with bends and welds: Without zoning/orientation, outer arcs go thin and weld toes may peel. Make outer arcs and weld toes their own zones and add weighting/masking — thickness and lifetime stabilize.
4) Write the process window clearly (easier talk on lead time & cost)
Wet-film limit per pass: Set different limits for flat areas, hole rims, and outer arcs (e.g., flat 1.0×, hole rim 0.8×).
Dry/soak/cool: 100–200 °C dry to constant mass; ≥ 400 °C soak 10–15 min; forced cool to room temp before the next pass (common for brush-coat + sinter MMO titanium anodes).
QC alignment: CMM points cover hole pitch and slot positions; zoned Ra, pinhole/spark thresholds, and white-cloth wipe all use the same 3D zone names, so reports are traceable.
5) One-look acceptance checklist
Does the quote include a 3D-exported zoned area table?
Are orientation, masking, and fixtures confirmed in one 3D sketch?
Do weak zones (hole rims / outer arcs / slot bottoms) have weighted coats or drain aids defined?
Do reports follow the same zone names for thickness photos, white-cloth wipe, spark threshold, and AST conditions/hours?
Summary
A 3D model with a zoned area table lets us lock orientation, masking, and fixtures up front. That connects Quote (g/㎡ × area) → current/voltage/time → QC in a closed loop. You get:
More accurate quotes (no over- or under-use of precious metal)
More stable lifetime (tighter thickness spread, repeatable AST)
More reliable lead times (less rework, clearer cycle)
This is why choosing a supplier who can handle machining + CAD + coating process brings the most direct value when sourcing MMO titanium anodes / platinum coated titanium anodes / titanium mesh anodes.
Coefficient Method for Titanium Mesh Anodes: count the slanted rib area too
In one line for buyers
A titanium mesh anode is not just “sheet area − open area”. After expansion, the mesh ribs are slanted, so the real coating area is larger than the flat projection. If you price or set process by flat area only, your quote will be wrong, and the chain g/㎡ → current density → thickness → lifetime will drift.
We use a coefficient method that includes slanted ribs, open area, and rib geometry—so price, g/㎡, and process stay aligned. This fits MMO titanium anodes (Ru–Ir/Ta) and platinum coated titanium mesh for chlorination, seawater treatment, cathodic protection, PCB/electrolysis, etc.
1) Why flat (projected) area is not enough
Slanted ribs aren’t counted: Expanded mesh ribs are angled; real surface > flat surface.
Open area “looks similar” but isn’t: With the same open rate, different hole shapes / rib thickness / stretch angle give very different real areas.
Process drifts: If area is wrong, your g/㎡, current/voltage/time, and finally thickness & lifetime will be off.
Bottom line: mesh must use Projected Area × Coefficients, or your pricing and process won’t match reality.
2) Our coefficient method (how we calculate)
Working formula (easy to share internally)
Effective coated area ≈ Projected area × K1 (hole shape & open rate) × K2 (rib geometry) × K3 (tilt/stretch correction)
Where do K’s come from? From repeated measurement + weighing + local cross-sections, then checked against AST (accelerated lifetime) results.
After samples are approved, the same mesh family can reuse the same coefficient set.
| Influence factor | What it changes | How we handle it |
|---|---|---|
| Hole shape (diamond/long/hex) | Slanted area ratio | K1 base by hole shape |
| Open rate (%) | Effective area up/down | K1 tiered adjustment |
| Rib thickness/width | Slanted area amount | K2 geometry (incl. edge radius) |
| Stretch angle/ratio | Rib tilt vs projection | K3 tilt correction |
| Surface roughening / blasting | “Apparent area” & paint hold | Folded into K2 via weigh/section checks |
We write these K’s into the 3D area table. That becomes the only reference for quoting and for g/㎡ calculation—no misunderstandings.
3) How quoting and process stay in sync (at a glance)
| Stage | What we provide | What you gain |
|---|---|---|
| 3D area table (with K’s) | Projected area + K1/K2/K3 math | Quote matches reality (no overpay) |
| Process sheet | Area → g/㎡ → I/V/t → masking/weighted coats/drain aids | Smoother thickness, predictable takt time |
| Sample data pack | Weighing & cross-section images, Ra by zone, white-cloth test, AST hours/conditions | Freeze window; copy to mass production |
| Mass parameter sheet | Bound to REV / fixture / furnace / coefficient version | Stable batches, complete traceability |
4) Buyer questions we solve (price, lifetime, lead time)
a) Will the price match real manufacturing?
We don’t use a flat “sheet area”. We use area × coefficients, so precious metal usage tracks real surface. No hidden overpay.
On repeat orders, we keep the same coefficient set, so pricing is verifiable and consistent.
b) Will thickness & lifetime be stable?
g/㎡ and I/V/t are set from the real area, so thickness distribution is tighter.
Under the same AST window, results are more repeatable and batch variation drops.
c) Will lead time be predictable?
We lock the cycle: wet-film limit per pass, 100–200 °C dry, ≥ 400 °C soak 10–15 min, forced cool to room temp, repeat.
For weak spots (tips/edges/junctions) we define weighted coats / drain aids early → fewer reworks, more stable timing.
5) A quick example (kept short)
A platinum coated titanium mesh priced by “sheet area − holes” looked expensive. After applying our coefficient method, the effective area dropped to the real level, pricing and g/㎡ were corrected, and AST consistency improved. After the first approval, the same coefficients were reused for batch orders—lower cost swings, smoother communication.
6) Process window (so production and QC speak the same language)
Wet-film per pass: Slightly lower than plate parts for mesh (e.g., 0.8×) to avoid runs/orange peel.
Dry/soak/cool: 100–200 °C dry to constant mass; ≥ 400 °C soak 10–15 min; forced cool to room temp before the next pass.
Weighted coats / drain aids: Add where needed (tips, edges, intersections).
QC alignment: Pinhole/spark thresholds by zone; cross-sections/weigh stats tied to the coefficient version; white-cloth photos archived by zone name.
7) One-page acceptance checklist
Does the quote include a 3D area table + K1/K2/K3?
Are g/㎡, current density, and time derived from that same area basis?
Do sample reports show weighing/cross-section/AST tied to the same coefficient version?
For mass builds, are REV / fixture / furnace / coefficient version frozen and traceable?
Summary (your practical benefits)
Using the coefficient method to include slanted ribs and open-mesh geometry brings quotes, g/㎡, and process onto the same, real surface. You get:
More accurate pricing (no overpay, no after-the-fact adjustments)
More stable lifetime (repeatable AST, tighter batch spread)
More reliable lead times (fewer reworks, clear takt)
This is why, when sourcing MMO titanium mesh anodes / platinum coated titanium mesh / expanded metal titanium anodes, it pays to choose a supplier who can CAD it, machine it, and set the coating process—all in one.
Chapter 4：Summarize
Ehisen wants you to know
At Ehisen, we believe the best results come from clear rules and shared data. For titanium anodes, that starts with agreeing on how coating area is calculated and how the process is derived from that area. We convert your 2D drawing into a clean 3D model with named zones (faces, edges, holes, bends, welds) and deliver a zoned area table. This becomes the common anchor for g/㎡ loading, current/voltage/time settings, and final cost—so quotes match the metal you actually need, no more, no less.
From there, we make execution transparent. Together we confirm which regions are coated or masked, the part orientation and fixtures, and practical limits like wet-film per pass, 100–200 °C drying, ≥400 °C soak, forced cooling. Weak areas (hole rims, outer arcs, slot bottoms) get weighted coats or drain aids. The result is more uniform thickness, repeatable AST lifetime, and fewer reworks—keeping your lead time and budget under control.
You set the priority; we tune the method. If cost control matters most, we focus on accurate area and precious-metal usage. If lifetime matters, we optimize loading and cycle windows. If timing matters, we freeze takt and checkpoints. You receive plain-language deliverables—zoned area table, a short process sheet (area → g/㎡ → I/V/t), and a sample data pack—so approvals are fast and the numbers are traceable inside your team. Our goal isn’t to look special; it’s to make pricing, process, and quality clear enough that we solve problems together—sustainably.
Supply & services
Our value go beyond titanium processing
Finding a reliable processor of titanium products is essential to your business success, and Ehisen is here to be that partner.
