Production Process for General & Bathroom Hardware Fittings

Part 1: General Production Process for TAKY Hardware Fittings
This foundational process applies to all TAKY hardware (e.g., sofa legs, cabinet feet, furniture hinges) and consists of 10 core stages, ensuring consistency in durability and precision.
1. Demand-Driven Design & R&D
The process starts with market and user need analysis—collecting insights from furniture manufacturers, interior designers, and end-users to identify functional requirements (e.g., load-bearing capacity) and style trends (e.g., minimalist aesthetics). TAKY’s R&D team uses CAD and 3D modeling software to create detailed blueprints, specifying dimensions, material grades, and structural details. Each design undergoes simulation testing: for example, furniture legs are tested for load-bearing via computer-aided stress analysis, while hinges undergo virtual opening/closing cycle simulations to verify lifespan. Only designs meeting international standards (e.g., ANSI, BS EN) proceed to prototyping.
2. Certified Raw Material Sourcing & Inspection
TAKY prioritizes materials that balance strength and durability, with sourcing tailored to product use:
Metal materials: 304/316 stainless steel (corrosion-resistant), solid aluminum alloy (lightweight), and reinforced zinc alloy (cost-effective for non-heavy-duty parts).
Auxiliary materials: EPDM rubber (anti-slip pads), food-grade plastic (lightweight components), and high-strength screws (installation hardware).
All materials are sourced from ISO 9001-certified suppliers. Upon arrival, TAKY’s QC team conducts three-tier inspections:
Chemical composition testing: Using spectrometers to confirm stainless steel nickel content (ensuring corrosion resistance).
Dimensional verification: Checking raw material size accuracy with digital calipers (tolerance ±0.01mm).
Defect screening: Visual and magnetic particle testing to detect cracks, impurities, or surface flaws. Unqualified materials are rejected immediately.
3. Precision Cutting & Blanking
Raw materials are transformed into "blanks" (semi-finished shapes) using advanced equipment:
Laser cutting machines: For metal sheets (e.g., sofa foot bases), delivering burr-free cuts with ±0.02mm precision.
CNC saws: For metal rods (e.g., furniture leg blanks), ensuring uniform length for batch production.
Shearing machines: For thin metal plates (e.g., small cabinet foot components), optimizing efficiency for high-volume orders.
Each blank is marked with a unique batch number for full traceability across subsequent stages.
4. Shaping & Forming: From Blank to Component
Blanks are shaped using processes matched to material and design complexity:
Stamping: For flat or slightly curved parts (e.g., hinge plates). Hydraulic presses (up to 200 tons) press blanks into custom molds, creating holes, grooves, or decorative patterns in one step.
Casting: For complex 3D shapes (e.g., vintage-style furniture legs). Molten metal is poured into sand or metal molds, cooled, and demolded—TAKY uses low-pressure casting for aluminum parts to reduce porosity and improve density.
CNC machining: For precision components (e.g., threaded holes in furniture legs). CNC lathes and mills carve blanks with micron-level accuracy, ensuring parts fit together seamlessly during assembly.
5. Heat Treatment for Enhanced Mechanical Properties
Metal components requiring high strength (e.g., load-bearing legs, hinges) undergo targeted heat treatment:
Annealing: Heating metal to 600–900°C and cooling slowly to reduce internal stress, preventing deformation during subsequent processing.
Quenching & Tempering: For high-strength parts (e.g., heavy-duty sofa legs). Metal is heated to 800–1000°C, rapidly cooled in water/oil (quenching) to increase hardness, then reheated to 200–500°C (tempering) to balance hardness and toughness.
Surface hardening: For wear-prone parts (e.g., hinge pivots). High-frequency induction heating creates a hard outer layer (HRC 40–45) while keeping the core flexible.
Post-treatment, components are tested with a Rockwell hardness tester—only those meeting standard values proceed.
6. Surface Treatment: Aesthetics + Protection
This stage enhances both visual appeal and longevity, with finishes tailored to material and use case:
Polishing: Abrasive belts or buffing wheels create smooth, shiny surfaces (common for stainless steel parts).
Electroplating: Coating with chrome, nickel, or gold. Chrome plating boosts corrosion resistance, while gold plating caters to high-end furniture needs.
Powder coating: Spraying dry powder (e.g., matte black, wood-tone) and curing in ovens (180–220°C) for scratch-resistant, eco-friendly finishes (RoHS-compliant).
Anodizing: For aluminum parts (e.g., lightweight legs), forming a colored oxide layer that resists fading and wear.
7. Assembly: Automated Precision + Manual Oversight
For multi-component products (e.g., furniture legs with rubber pads, hinges with screws), assembly is conducted in dedicated workshops:
Component sorting: Parts are matched by batch number to ensure compatibility.
Hybrid assembly: Automated machines attach standard components (e.g., rubber pads) for speed, while skilled workers handle precision tasks (e.g., installing hinge springs) to avoid damage.
Torque testing: Screws and fasteners are tightened to specified torque (e.g., 5–8 N·m for furniture legs) using digital torque wrenches, preventing loose parts or over-tightening.

8. Multi-Stage Quality Control (QC)
TAKY implements in-process and final QC to eliminate defects:
In-process checks: Inspectors sample 5% of parts per stage (e.g., cutting dimensions, heat treatment hardness) and reject batches with >0.5% defects.
Final product testing:
Load-bearing test: Furniture legs are subjected to 120% of rated load (e.g., 96kg for 80kg-rated legs) for 24 hours.
Durability test: Hinges undergo 50,000+ opening/closing cycles (equivalent to 15+ years of use).
Visual inspection: Checking for surface flaws (e.g., uneven plating, scratches) and logo clarity.
Only products with a "QC Pass" label move forward.
9. Protective Packaging
Packaging is designed for transportation safety and user convenience:
Inner packaging: Each product is wrapped in anti-scratch plastic or foam; small parts (e.g., screws) are sealed in labeled bags.
Outer packaging: Corrugated cardboard boxes with reinforced corners (bulk orders) or color-printed boxes (retail) featuring product details (model, material, installation instructions).
10. Warehousing & Global Shipping
Qualified products are stored in climate-controlled warehouses (15–25°C, 40–60% humidity) to prevent rust or mold. TAKY leverages 3 regional warehouses (Asia, Europe, North America) for fast delivery (3–7 days for regional orders) and provides customs-cleared documents for international shipments.

Part 2: Specialized Production Process for TAKY Bathroom Hardware
Bathroom hardware (e.g., shower clamps, glass door hinges, shower hinges) faces unique challenges—constant exposure to water, steam, and cleaning chemicals. TAKY adds 4 specialized stages to the general process, focusing on corrosion resistance, water tightness, and safety.
Key Differences from General Hardware Production
1. Material Upgrade: Corrosion-Resistant Core
TAKY exclusively uses 316 stainless steel (instead of 304) for critical bathroom components (e.g., shower clamps, hinges). 316 stainless steel contains molybdenum, which enhances resistance to chloride corrosion (common in bathroom water and cleaning products). For high-end lines, solid brass is used—its excellent 延展性 allows complex shaping, and it accepts plating (e.g., chrome, gold) seamlessly while remaining rust-proof.
2. Enhanced Shaping: Water-Tightness Optimization
Precision casting for hinges: Shower hinges use investment casting (instead of sand casting) to create smooth, pore-free surfaces—eliminating water accumulation points that cause rust.
Seamless stamping for clamps: Shower glass clamps undergo one-piece stamping (no welding) to avoid seam leakage. Welded components (e.g., glass door brackets) receive post-weld electrochemical polishing to eliminate "贫铬层" (a corrosion hotspot) and ensure uniform anti-rust performance.
3. Advanced Surface Treatment: Long-Lasting Anti-Rust Protection
TAKY adopts a triple-layer plating system for bathroom hardware, exceeding industry standards:
Base layer (copper): Fills micro-pores on the metal surface, improving subsequent plating adhesion.
Middle layer (nickel): Creates a barrier against moisture penetration, boosting corrosion resistance.
Top layer (chrome/gold): Provides a hard, scratch-resistant finish that retains shine and repels water.
For stainless steel parts, TAKY uses nanoscale 钝化 technology: A 稀土 - organic acid composite 钝化液 forms a 2.8–3.2nm dense Cr₂O₃ film on the surface, increasing corrosion resistance 17-fold compared to traditional processes. This enables parts to pass 480-hour neutral salt spray tests—meeting EU and North American export requirements.
4. Specialized Testing: Water Tightness & Safety Focus
In addition to general QC, bathroom hardware undergoes two exclusive tests:
Water leak test: Assembled shower clamps/hinges are installed on 8–12mm tempered glass panels, then sprayed with 30PSI water (simulating shower pressure) for 1 hour. No leakage at seams or connections is required.
Glass compatibility test: Hinges are mounted on standard tempered glass and tested for 10,000 opening/closing cycles to ensure no glass cracking from uneven pressure.
Example: Production Flow for TAKY Shower Hinges
Design R&D → 2. 316 stainless steel sourcing & inspection → 3. CNC cutting → 4. Investment casting → 5. Heat treatment (quenching + tempering) → 6. Electrochemical polishing + triple-layer plating → 7. Assembly (with EPDM gaskets) → 8. Leak test + 50,000-cycle durability test → 9. Packaging → 10. Shipping.
Why TAKY’s Production Process Stands Out
Material specificity: Tailoring materials to environment (316 stainless steel for bathrooms) ensures longevity.
Technology integration: Combining automated precision (CNC machining) with craft expertise (hand-polishing for high-end parts) balances efficiency and quality.
Test rigor: Exceeding international standards (480-hour salt spray tests, 50,000-cycle durability tests) minimizes post-purchase issues.
Traceability: Batch number tracking from raw material to delivery enables rapid issue resolution.
Whether for general furniture hardware or specialized bathroom fittings, TAKY’s production process embodies its commitment to "safety, durability, and user-centricity."