6061 Aluminum CNC Machined Laser Welding Gun Head Manifold Body with 0.01mm Port Fit for Battery Tab Welding

This body is the machined core of a laser welding gun head. It distributes shielding gas and purge air, carries coolant around the optics, and provides the mounting interface for the lens drawer and the nozzle. Because it is machined from solid 6061-T6 rather than cast, there is no porosity to leak through and no draft angle to fight when the seal faces are cut.

The head body sits on a battery tab welding station, where it carries the shielding gas, the air purge and the cooling circuit around the optical path. Three things have to be right at once: the ports must land where the mating fittings expect them, the internal cavities must not leak, and the machined faces around the beam exit must not obstruct the lens. A body that is 0.03 mm off on port position forces the assembly line to shim the fitting, and a body that leaks air into the gas chamber shows up as porosity in the weld.

We machine the cavities, ports, sealing faces and the optical clearance in one clamping from a 6061-T6 block, hold port position to 0.01 mm and cavity floor flatness to 0.015 mm, then leak test the gas and cooling circuits before anodizing.

1. 1Drawing and flow review. We check the circuit schematic against the 3D model, confirm port threads, seal face widths and wall thickness, then quote within one working day.
2. 2Material verification. 6061-T6 plate is checked for grade and temper against the mill certificate and inspected for internal soundness on critical bodies.
3. 3Stress relief and facing. The block is stress relieved and faced on all six sides, so every cavity depth is measured from a true datum.
4. 4Cavity machining. Rectangular chambers and the main cylindrical bore are roughed and finished with a controlled step-over, keeping floors flat and walls square.
5. 5Cross-drilled passages. Passages are drilled from the model with depth control, then deburred through the cavity so no chip or burr narrows the flow path.
6. 6Ports and threads. Threaded ports are drilled, tapped or thread-milled, then checked with go / no-go gauges at the specified depth so a fitting cannot bottom on a thread.
7. 7Leak test. Gas and coolant circuits are pressure tested separately at 0.6 MPa with an air decay method, and the result is recorded before finishing.
8. 8Anodizing and final inspection. Clear or black anodizing with seal faces and threads masked, then CMM for port position and cavity geometry, with a first article report in the carton.

Ports are drilled after the cavities are finished, so any error in the cavity datum shows up at the fitting. We keep one datum scheme through the whole programme: the same face that locates the cavity also locates the port, and the port is checked on a CMM rather than by eye. Threads are cut to a controlled depth so a fitting seats on its face and not on the last thread, which is a common cause of a gas leak that only appears after the line has warmed up.

Cavity layout, port count and thread type, seal face width, cooling path, mounting interface and anodizing colour are all built to your drawing. One piece is a normal order with no tooling charge and no setup fee, and the prototype follows the same leak test and inspection plan as the batch. If a passage cannot be drilled without breaking into another circuit, our engineer returns a DFM note with an alternative routing before machining.

• NDA before files. Mutual non-disclosure is signed before drawings, models or samples are released, covering geometry, volume, end use and customer identity.
• No public reference. Confidential bodies never appear as samples, catalogue items, website photos or trade show parts.
• Separated cell. Sensitive work runs with named operators, and programmes and fixtures are stored under a project code.
• Partner control. Anodizing suppliers receive process specifications only, never the assembly drawing.

Dongguan Changxinda Precision Technology Co., Ltd has machined custom parts since 2008 and runs four-axis and five-axis machining centres, turn-mill lathes, CNC lathes and milling machines. The plant employs 90 to 102 people under ISO 9001:2015, serves more than 200 customers, exports 50 to 60 percent of output and records annual sales of USD 10 to 20 million.

• Dates in writing. Prototypes 5 to 8 working days, batch orders 18 to 28 working days after drawing approval.
• Repeat orders skip setup. Programmes, fixtures and leak test fixtures stay on file.
• Reserved slots. Blanket orders are booked into fixed monthly machine time.
• Early notice. If material, anodizing or leak testing threatens the date, you hear it before it is missed.
• Dispatch evidence. Photos, inspection and leak reports, packing list before shipment.

• ✅ Consumer Electronics: phone, tablet and laptop housings, heat sinks, camera brackets, VR/AR headset structural parts, smart wearable shells
• ✅ Automation & Industrial Equipment: automation fixtures, jigs, module frames, transmission sliders, motor mounts, sensor housings, conveyor line parts
• ✅ Semiconductor & Vacuum Equipment: vacuum chambers, vacuum fittings, precision equipment bases, thermal isolation and insulation parts, inspection fixtures
• ✅ Medical Devices: surgical instrument bases, diagnostic instrument housings, endoscope components, aesthetic device structural parts (medical-grade aluminum and stainless steel)
• ✅ Automotive: new energy motor housings, battery end plates, sensor brackets, lamp structural parts, tuning parts, hydraulic valve blocks
• ✅ Aerospace & UAV: aircraft structural parts, drone frames, landing gear parts, avionics instrument housings (lightweight precision parts)
• ✅ Optics & Photonics: optical lens barrels, lens mounts, light source heat sinks, camera module brackets, inspection optical benches
• ✅ Communications: 5G heat dissipation cavities, filter parts, signal adapter structural parts, telecom equipment housings
• ✅ Robotics: robot arm joint parts, robot bases, reducer housings, AGV structural parts
• ✅ Instrumentation: test equipment housings, precision gauge bases, flow meter parts, laboratory equipment accessories

Each body is bagged with desiccant, seated in an EPE cavity tray so seal faces and ports cannot be bruised, then sealed in a moisture barrier bag. The tray fits a five-layer export carton printed with part number, quantity and batch code. Sea freight ships on fumigation-free plywood pallets; neutral cartons are available.