Everything you need to know about the design and manufacture of automotive metal racks

The design and production of metal racks for the automotive sector represent fundamental processes that must be carried out to the best of their ability to ensure efficiency and safety in the handling of automotive components. Ferrero Automotive stands out in the landscape of metal racks manufacturers thanks to a highly customized approach, the use of superior materials, and the development of advanced technologies.

Let’s look more specifically at how the design and manufacturing processes of metal racks are carried out and all the advantages of custom-made racks produced by Ferrero Automotive.

How metal racks design takes place

The design of automotive metal racks begins with a detailed 3D model provided by the customer. This approach makes it possible to optimize spaces according to the components to be handled, reduce the margin of error from the earliest stages, and customize every technical detail according to the specific needs of each production line.

The process is based on the use of advanced CAD software that allows the finished product to be visualized before production. Ferrero Automotive’s technicians work directly with customers to analyze the required specifications, evaluating key aspects such as weight, dimensions, loading/unloading methods and type of handling. This preliminary phase is essential to ensure a perfectly functional final product that meets operational needs.

Through virtual simulations and structural analysis, any critical issues can be identified and corrected before production, saving considerable time and resources. In addition, the creation of 2D construction tables supports the creation of prototypes, which can be verified through the use of 3D printers capable of faithfully reproducing the designed components.

The production process of automotive metal racks

Once the design phase is completed, following the final approval of the prototypes, the actual production of automotive metal racks is carried out, first in pre-series and then in series.

The main production stages and technologies include:

• laser cutting: this technique allows component templates to be obtained from high-quality steel sheets, ensuring millimeter accuracy;
• CNC bending: the cut shapes are subsequently bent with CNC machines, ensuring precise and repeatable bends;
• assembly and welding: the bent parts are then assembled through robotic and manual welding techniques and machinery, ensuring perfect consistency with the initial design and maximum structural soundness.

This highly technological and rigorous production cycle makes it possible to produce reliable, strong and durable metal racks that perfectly meet customers’ specific requirements

Ferrero Automotive’s metal racks are made from certified, high-quality materials such as high-strength steel and stainless steel. High-strength steel is known for its strength and long service life, making it the ideal choice for racks designed to withstand high loads and intensive use. Stainless steel, on the other hand, is noted for its excellent corrosion resistance, making it particularly suitable in environments where exposure to moisture or corrosive agents could compromise other materials.

To ensure high precision and adherence to the tolerances required for metal racks used in automotive systems on robotic lines, Ferrero Automotive subjects all its products to rigorous dimensional checks. To this end, advanced measurement tools, including 6-axis 3D arm machines, are used. This process makes it possible to produce racks that conform to customers’ technical specifications and are perfectly adaptable to the needs of each production line.

The benefits of custom-made automotive metal racks

In the automotive sector, the use of custom-made metal racks brings with it numerous benefits, ranging from better protection of components to the simplification of logistics activities and the possibility of adapting them to the company’s specific needs. Among the main benefits of their use are:

• logistics optimization: the use of specific metal racks allows for leaner and faster handling of parts, reducing handling time and improving efficiency along the production chain;
• high protection: thanks to their robust construction, these racks provide excellent defense against shock, vibration and unfavorable environmental conditions, keeping parts safe during all phases of transportation and storage;
• easy handling and storage: made according to the specific characteristics of the components to be contained, these racks facilitate both storage in warehouses and transportation within production lines;
• customization: racks can be adapted according to the company’s needs, allowing for improved component management and more efficient operational flow;
• environmental sustainability: metal racks, thanks to their long life and reusability, make it possible to reduce waste generation and resource consumption.

Why choose metal racks designed and manufactured by Ferrero Automotive?

Ferrero Automotive is a well-established supplier of automotive metal racks thanks to a solid experience in the field and the ability to meet the specific needs of each customer by taking advantage of advanced technologies, such as 3D modeling and CAD software.

The company stands out among automotive metal racks manufacturers for its ability to provide comprehensive service, from initial consultation to after-sales support, supported by a highly qualified team. Ferrero offers three main types of automotive metal racks:

• specific metal racks: custom designed and manufactured to meet the precise needs of each automotive component;
• metal racks with stacker pillars, special equipment designed for loading and unloading parts using robots, ideal for optimizing handling and storage while offering strength and ease of use. Used in robotic lines, they allow maximum automation, speed and efficiency of production processes.

Choosing Ferrero Automotive means relying on a partner that puts quality, precision and continuous innovation at the center of its work. If you would like more information, please contact us!