With the burgeoning smart lock market, consumer preferences are diversifying. The demand varies in terms of craftsmanship, materials, and features. This diverse demand has propelled a myriad of intelligent door lock products with different materials and techniques. How much do industry professionals really know about this?

1. Common Forging Processes for Smart Locks

Currently, the two predominant forging methods in the industry are die-casting and CNC precision carving. Die-casting involves heating metals to high temperatures and then pressing them into molds, followed by cooling and product extraction. CNC, on the other hand, employs high-speed precision carving with small tools. The processes differ significantly:

Die-casting Process:

1. Design aesthetics, formulate product structure, followed by 3D prototyping.
2. Selection of product components and production process planning.
3. Development of product and component molds.
4. Product trial assembly optimization.
5. Mass production.

Note: Products made using die-casting typically take around two to three months from development to mass production, or even longer.

CNC Process:

1. Design aesthetics, establish product structure.
2. Planning of production techniques.
3. Physical prototyping and optimization.
4. Proceed to mass production post-optimization.

Note: Products crafted with CNC carving usually take about a month from development to mass production.

Currently, the industry primarily relies on these two product categories, with a few brass and stainless steel products sprinkled in.

Die-casting vs. CNC Differences

Die-casting Products:

• Industry primarily uses zinc and aluminum alloys. While zinc was predominant in the early days, the shift to aluminum alloys occurred later due to cost considerations. Earlier products predominantly showcased electroplating finishes, with zinc alloy exhibiting superior finish quality. Presently, aluminum alloy products largely feature paint baking and powder spraying, which are cost-effective.

CNC Carved Products:

• The industry predominantly employs 6063 aerospace-grade aluminum. Depending on the design, specific molds are created for production. The surfaces typically undergo anodizing for a superior finish, offering corrosion resistance. However, the downside is its higher cost.

2. Forging Material Variations

Smart lock materials are primarily categorized into base and surface materials. As of now, the base materials include aluminum alloy, aerospace-grade aluminum, zinc alloy, and stainless steel. Surface materials encompass toughened glass and acrylic.

Base Materials:

❶ Aluminum Alloy:

• A prevalent choice for entry-level smart locks due to its cost-effectiveness. However, its surface hardness is relatively low.

• Limitations include difficulty in achieving fine polishing, usually featuring ordinary paint and enamel finishes, resulting in a rough surface texture.

❷ Aerospace-Grade Aluminum Alloy:

• Generally referring to the 6-series and 7-series aluminum alloys, they are precision-cast and machine-friendly. They’re lightweight but exhibit high density, strength, and relatively lower toughness.
• Finishing includes anodizing for a matte finish and brushing, though the latter compromises friction resistance.

❸ Zinc Alloy:

• Widely utilized due to its density, toughness, and malleability. The casting involves melting the zinc alloy at high temperatures, followed by casting.
• Post-processing includes coloring after brushing, mimicking a coppery finish. However, its lateral friction resistance is relatively lower.
• Electroplating with chrome is the most widespread finish. It provides a durable coating with superior corrosion resistance.

❹ 304 Stainless Steel:

• Known for its high hardness, it poses challenges in processing. Typically, it’s 2mm strip steel processed via stamping. It’s challenging to shape with sharp corners due to its inherent properties.
• While it can be brushed and then electroplated, achieving consistent coloring is challenging due to its inert nature.
• Beware of products claiming to be 304 stainless steel but are actually 201, which tends to rust over time.

❺ Brass:

• Due to its high cost, it’s primarily reserved for villa locks. It’s cast and then machined.
• Surface treatments include oxidation coloring, brushing, and original sandblasting. Brass, being highly corrosion-resistant, becomes more aesthetically pleasing over time with natural oxidation.

Surface Materials:

❻ Acrylic Panels:

• These have a softer base with lower surface hardness and are susceptible to scratches.

❼ Toughened Glass:

• With high hardness and resistance to scratches, it’s five times costlier than acrylic. However, it poses challenges in processing and isn’t suitable for bending.

❽ 5A Diamond Screen:

• Refers to acrylic panels or IMD-treated panels with a nanocoating for reduced friction and enhanced durability.

By delving deep into these materials and processes, one gains a profound understanding of the intricacies of smart locks, allowing for informed decisions and better client interactions.