Technology

Our technical team is equipped with design, engineering, and manufacturing capabilities accomplishes, allowing us to create SAI forged products using computer-aided design (CAD), computer-aided engineering (CAE), and computer-aided manufacturing (CAM).

Design

The capacity of our technical team includes mold design and manufacture; design, development, flow analysis of forging molds, machining of high-precision products, surface polishing and optimization, and painting. During the design and development phase, finite element analysis is applied to calculate the optimal structure to shorten the design and development lead-time, save costs, and deliver optimal lightweight designs. With capabilities covering 3D design, structural design, high-quality curvature modeling, motion simulation, finite element analysis, reverse engineering, and craft design applicable to the aerospace and automotive industries, we provide bespoke products for customers demanding a streamlined style.

Production

1

Forging

After crosschecking the simulation results of forging mold flow simulation and analysis with different types of mold flow analysis software, judgement and revision are eventually made based on the forging know-how accumulated over the years to prevent potential defects and search for the optimal process condition and design.

2

Machining

In response to customer demands for diversity, low volume, high-precision, and complex curvature, we write machining programs with advanced CAM to integrate high precision with high-quality curvature 3D to produce products with optimal surface precision and assembly.

3

Polishing

Professional technology and equipment are used in polishing for surface optimization. Mechanical polishing, dynamic polishing, and ceramic polishing techniques are applied to present the natural luster and color of forged aluminum according to the appearance requirements of customers.

4

Painting

Robotic arms are equipped on the entire painting line to meet different paint and luster requirements and control appearance quality through automation. Since products are getting increasingly complex nowadays, we fulfill the diversified demands of our customers with masking, machining, laser engraving, pad printing, and HRNT.

Forging Process

SAI’s main product is forged aluminum alloy wheels. We have two different manufacturing processes to meet all kinds of customer needs.

CNC forging can maintain high design freedom, while net shape forging can save the complex and long cycle time of machining for mass production.

01

Aluminum ingot
02

Forging

Pre-forging
Pre-forging Rough forging Fine forging
03

Flow-Forming
04

Machining Polished surface optimization
05

Painting
06

Lathing Polished surface optimization
07

Milling Polished surface optimization

CNC Forging

Net Shape Forging

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High cleanliness aluminum ingots produced by energy-efficient manufacturing processes meet the stringent demand for functionality and carbon reduction of customers. Additionally, we also accept customization of aluminum alloy.

Pre-forging

Materials consumption and allocation are determined based on the style and structural demands of customers. Primary forging press delivers high contour stability, with high design freedom provided by a multiple machining process.

Pre-forging

Materials consumption and allocation are determined based on the style and structural demands of our customers.

Rough forging

Form the rough shape and optimize materials allocation between pre-forging and fine forging.

Fine forging

Directly form the design surface according to the style and flow-forming requirements of customers. Optimize fatigue performance through grain flow design. Save the expensive cost of machining cycle time with outstanding forging technology. Suitable for mass production to address the requirements of increasingly tightening energy and emission reduction requirements.
The highest level of flow-forming technique delivers the best rim performance in the forged wheel industry. (Above: CNC forging/ Below: Net shape forging)

Appearance

Fully Painted

Fully Painted is a classic surface finish. Different paints can be developed for special colors. Together with background painting with professional powder varnishes, oil-based paints, or water-based paints on the automated production line, a velvety product surface is presented.

Bicolored – Natural aluminum color + selected color

After polishing different positions and angles with professional techniques, the polished areas are covered with special masking for painting with different colors to present a bicolored appearance containing the glossy luster of aluminum and the selected color.

Bicolored – Two selected colors

With multilayer painting and baking techniques, different colors and special masking, the high-quality bicolored visual effect is presented for products to accentuate a strong sports style.

Ceramic Polish

Professional polishing equipment is used to optimize the surface finish to maintain an even luster while presenting sharp and glossy effects without sacrificing high brightness. Together with professional painting techniques, a mysterious matte effect is delivered in the appearance.

Mirror Polish

Professional polishing equipment is used to optimize surface finish to present the natural color and luster of aluminum and deliver a mirror effect.

PVD Vaccum plating (Sputerring)

Unlike traditional spray painting, PVD is a power-coat for wheels that gives the look and feel of chrome without the extra added weight. It is a special painting technique using metal paints to present a mirror-like appearance.

Multilayer painting with lathing and milling

The multilayer painting technique is combined with lathing and milling to create a clean geometric gradation effect. It is often used on extremely high-end custom products. After machining, fine grinding and polishing are implemented manually to present a unique visual effect.

Accessories

In response to the demand for lightweight products in the future, we assist customers in developing carbon fiber or plastic accessories and provide fastening solutions and insertion/withdrawal test services. Apart from creating rich visual effects with our patented multilayer painting technique with lathing and milling, we also meet the demands for lightweight, multicolor, and composite materials use.

Custom patterns

Custom patterns can be presented at the designated positions with techniques including laser engraving, pad printing, and HRNT. Protection is also provided to prevent patterns from damage by exterior wear.
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