The development timeline varies depending on product complexity and technical requirements. In general, a standard project development cycle ranges from 3 to 5 months, covering the complete process from conceptual design and tooling development to validation and mass production readiness.

We provide full-process collaborative design capability, covering structural optimization, process simulation, and equipment integration. Our engineering team utilizes CAD 3D modeling, CAE finite element analysis, VC visual simulation, and VR virtual commissioning to create a fully digital R&D workflow to cover all the steps from concept validation through to mass production.
For example, in developing lightweight chassis tubing for a new energy vehicle customer, CAE simulation enabled optimized material distribution, reducing component weight by approximately 20% while maintaining collision safety standards. In addition, our independently developed production equipment, such as hydroforming systems, can be customized to meet customer-specific forming and precision requirements.

We apply an advanced digital ecosystem across design, manufacturing, and management:

• Design & Simulation
  SolidWorks, UG (3D modeling), ANSYS (structural analysis), AutoForm (forming simulation)
• Manufacturing & Programming
  FASTSUITE (6-axis laser cutting offline programming), HyperMill (5-axis machining programming)
• Production Management
  SAP ERP, MES Manufacturing Execution System, PDM Product Data Management
• Digital Factory & Industry Connectivity
  Based on 5G + Industrial IoT, supported by SCADA systems for real-time monitoring and OEE optimization.

We independently complete tooling design and manufacturing through our dedicated tooling R&D center and precision machining facility. Utilizing advanced tooling design platforms such as UG NX Mold Wizard and high-strength alloy steels, we achieve long service life and stable forming quality.
Tooling performance highlights include:

• Tooling life of up to 150 tons
• Single die output exceeding 80 cycles
• Finished yield rate above 70%
• Machining accuracy controlled within ±0.01 mm

Supported by 5-axis machining centers, EDM equipment, high-precision metrology systems (including CMM), and independently developed hydroforming tooling, we deliver reliable forming capability while reducing welding processes and improving efficiency.

Our technology capabilities are supported by 97 granted patents, including 43 invention patents, covering hydroforming, laser cutting, and other core processes.

• Cost competitiveness
  Independently developed integrated production lines cost approximately one-third of imported systems, while large-scale production (annual capacity exceeding 10 million pieces) further reduces marginal manufacturing cost.
• Green manufacturing
  Welding-reduction technologies achieve approximately 20 million meters annual weld length reduction, while distributed photovoltaic energy systems save about 3 million kWh of electricity annually, supporting low-carbon manufacturing.
• Rapid response
  One-piece flow production line combined with digital management shortens delivery cycles by approximately 30% compared with industry averages.
• Customer recognition
  Long-term partnerships with major OEMs including BYD, Volkswagen, and NIO. Hydroformed chassis component market share ranked first globally in 2024 (16.2%).

As of 2024, Motorbacs maintains an annual production capacity of 10 million parts, covering hydroformed chassis components for new energy vehicles, as well as key engine tubing products. Production layout includes more than 40 automated lines across bases in Ningbo and Anhui:

• Jiangbei Cicheng Plant: annual capacity of 3 million sets of new energy vehicle chassis components
• Chaohu Plant: daily production capacity of 15,000 components

By 2025, total capacity is planned to exceed 20 million units, supporting our goal to become a benchmark enterprise in lightweight chassis technology worldwide.

We have established a full-lifecycle quality management system, covering material inspection, process monitoring, and finished product verification.

• Certifications: IATF 16949:2016, ISO 14001 and other international system certifications.
• Inspection equipment: 3D measurement arms, spectrometers, salt-spray testing systems, and multiple precision inspection platforms enable 100% monitoring of material composition, dimensional accuracy, and corrosion performance.
• Process control: AI visual inspection and online laser measurement ensure stable quality with a zero-defect objective (PPM minimization).
• Continuous improvement: Lean manufacturing and Six Sigma methodologies support ongoing optimization. Our product yield has increased to 99.8% in recent years.

• Technology advancement: Continued R&D investment (annual R&D ratio above 8%), focusing on high-strength aluminum forming, intelligent CNC systems, and breakthrough technologies in critical areas.
• Capacity expansion: Construction of a 70,000 m² digital factory planned before 2025 to achieve annual output of 20 million automotive chassis tubing components, strengthening global competitiveness.
• Industry chain extension: Expansion into new product segments including air suspension components and hydraulic accumulator assemblies, while further integrating upstream resources such as laser systems and die steel.
• Sustainability: Accelerated implementation of photovoltaic power and energy storage solutions, targeting carbon-neutral manufacturing by 2030.

To determine the bending speed, it's necessary to consider the tube diameter, material, hardness, and wall thickness. Softer or thin-walled tubes are normally bent at a slower speed, so the tube does not lose its shape during bending. Heavy or harder tubes are more stable and can be bent more quickly without losing their shape. In most cases, the number of axes on a tube bending machine is determined by the complexity of the tubes that need to be processed. For small-diameter tubes with simple bends, 3- or 4-axis machines are usually enough. If the tube diameter is larger or if the bending geometry is complex, such as side or inclined bends, 5-axis bending machines or higher configurations usually provide better control and help maintain both shape and strength.

Planning an automated tube processing line starts with understanding the tube material, part geometry, and production volume. When planning a tube processing line, it is important to consider the process flow, equipment compatibility, automation level, and quality control. A good tube processing line has a suitable balance between flexibility and efficiency, focusing on what is actually needed for tube production instead of adding complexity that does not add real value.

The reliability of large tube bending systems is an important consideration for railway companies. They look for equipment that can deliver accurate transmission and positioning, stable power output, and consistent clamping performance. Long-term durability and built-in monitoring or safety functions are also important, along with efficient multi-axis coordination and low failure rates, to support the high reliability and batch production requirements of railway tube components.

Springback and cracking are mainly avoided by keeping the bending process stable, with controlled tube movement and consistent clamping force from start to finish. Full-servo control with repeat positioning accuracy of ±0.02 mm allows stable operation, while servo-monitored clamping forces of 250 kN for the main clamp and 200 kN for the auxiliary clamp help prevent part slippage. Online simulation is used to define suitable bending paths and avoid interference areas, with bending speed kept within appropriate limits of up to 70°/s. In addition, lubrication of the mandrel and wiper die reduces forming friction, and automatic weld seam detection helps avoid stress concentration zones, further reducing the risk of springback and cracking.

Lubrication is important during the bending of ultra-high-strength steel to limit friction between the tube and the tooling. Bending machines are equipped with lubrication systems for the wiper die and mandrel, operating at up to 2.5 MPa and 3 MPa respectively. Lubricants suitable for high-strength steel help reduce wear on the tooling and protect the tube surface during bending. Because this type of material places high stress on the tooling, molds are usually made from high-strength, wear-resistant materials, such as carbide tooling or tools with surface coatings, which helps prevent defects caused by insufficient lubrication or excessive tool wear during bending.

Compared with traditional stamping, the hydroforming process generally uses less energy because complex parts can be formed in a single step, instead of going through multiple operations and using various tools. Thanks to this, the whole process more efficient, allowing hydraulic system efficiency to increase from about 60% to around 85%, with energy savings of up to 25% per year. Since the pressure comes from inside the tube and is applied evenly, the material bends in a much more controlled way. This makes springback smaller and more predictable, usually around 0.1–0.3 mm. This level of control is especially useful when forming lightweight, high-strength tubes that require precise dimensions.

In oval or rectangular tubes, uneven thickness usually comes from poor pressure or feeding control. Managing these two factors properly helps the material flow more naturally and keeps the wall thickness more consistent. CNC hydroforming equipment allows pressure to be controlled within ±0.5 MPa and cylinder movement within ±0.1 mm, so material flow can be adjusted accurately. During the tube forming process, sensors track the cylinder movement with a resolution of 0.001 mm, which allows the feeding process to be adjusted in real time as the material flows. Combined with proper process design and pressure distribution, this approach allows the wall thickness to remain close to uniform across the entire tube section.

A 16-axis double-station 3D laser cutting machine is capable of cutting a wide range of complex geometries thanks to coordinated multi-axis motion from dual cutting heads. It can process flat surfaces, angled surfaces, and parts with multiple curved sections. Typical applications include irregular tubes, automotive body panels, and hot-formed steel components. In most cases, up to 99% of parts can be completed in a single setup, avoiding re-clamping and improving overall accuracy.

When selecting a 16-axis double-station 3D laser cutting machine, component manufacturers should focus on machining accuracy, such as axis repeatability, as well as efficiency-related factors like independent dual-head operation and maximum cutting speed. Process flexibility is also important, along with machine suitability parameters such as axis travel, maximum fixture load, and material compatibility. Programming efficiency and overall machine size should also be considered to ensure the system fits actual production requirements.

Weld stability is maintained through a combination of high-precision servo drive control, real-time feedback, and machine vision monitoring. Welding parameters are defined through pre-trials and adjusted dynamically during operation. High-power laser welding, seam tracking, and precise alignment help keep the weld stable even during long periods of high-speed production. High material yield (>96%) and compatibility with high-strength steels above 800 MPa further support consistent weld quality.

Key points include weld seam quality, equipment accuracy and stability, material adaptability, and the ability to monitor welding quality automatically. Pre-trial testing to define optimal welding parameters is also important to maintain a high material yield (>96%) and ensure stable performance during long-term operation.

Automation planning should focus on integrating the full process flow, including loading, edge milling, forming, welding, cutting, online eddy current testing, and robotic unloading. High-precision servo drives work together with vision and sensing systems to keep the line stable at high speeds, while allowing weld quality to be monitored in real time and automation to run smoothly.

Weld consistency can be controlled by selecting production lines equipped with high-precision servo drives and vision-based monitoring. Optimal welding parameters should be defined through pre-trials and adjusted in real time during production. Online eddy current testing further helps detect defects such as porosity or cracks, ensuring stable and consistent weld quality.

Flatness and hole accuracy are ensured through stable machining and precise measurement control. A BT50 spindle and rigid cross-slide guideways keep milling stable, while high-precision linear encoders control material removal in closed loop. Laser displacement sensors check the machined surface, and a CNC servo feed system adjusts the machining position and bevel/tilt angles within ±3°. A 25° inclined table with automatic chip removal prevents chip interference during machining.

Hydroformed subframe tubes help reduce vehicle weight by forming the structure as a single piece, which cuts down the number of parts and weld points. Variable cross-section hydroforming allows tube diameter and wall thickness to be optimized where loads are higher, achieving more than 20% weight reduction while maintaining strength and stiffness. As a result, vehicle energy consumption and emissions are reduced, while chassis performance remains unchanged.

After forming, high-strength steel tubes are usually protected with electrophoretic coating. Zinc phosphating is often applied as well, helping the coating bond better to the surface. For applications that require corrosion protection, hot-dip galvanizing can also be used to provide long-lasting durability.

Hydroformed frame components significantly reduce fatigue stress by cutting the number of weld joints by more than 60%, which helps avoid stress concentration at critical points. Shot peening is then applied to strengthen the material surface and improve fatigue resistance. With the extra stiffness gained from hydroforming, the structure handles repeated loads more easily, which helps extend fatigue life by around 25–30% and keeps the frame reliable even when working under heavy loads or on rough terrain.

When customizing precision metal bellows accumulators, energy equipment manufacturers primarily focus on high-pressure fatigue resistance, stability under both high and low temperatures, and low impurity characteristics of the bellows material. They also pay close attention to welding compatibility with the end caps to ensure reliable sealing performance and prevent high-pressure leakage.

Laser welding of high-strength steel produces minimal deformation at the weld seam, delivers high joint strength, and does not require post-weld heat treatment. When applied to new-energy vehicle chassis, strength, stiffness, and fatigue performance can be improved by 30–50%, while weight can be reduced by 10–30%. In addition, weld reliability is further ensured through flattening tests (no cracking), flaring tests (no tearing), metallographic control of fusion line width (0.02–0.11 mm), and streamline angle (50°–70°), helping prevent weld cracking during collisions and enhancing overall safety performance.

The characteristics of laser-welded high-strength steel tubes, such as minimal weld deformation, high joint strength, and no requirement for post-weld heat treatment, combined with strict metallographic control of fusion line width (0.02–0.11 mm) and streamline angle (50°–70°), as well as verification through flattening (no cracking) and flaring (no tearing) tests, significantly enhance weld reliability. As a result, fatigue strength of key structural components can be improved by 30–50% compared with conventional tubing, helping construction machinery withstand high-frequency, heavy-load operating conditions with enhanced durability.

Laser welding parameters must be adjusted according to the strength level and material characteristics of different high-strength steel grades, including optimization of laser power, welding speed, and related process parameters. Proper parameter matching ensures minimal weld deformation and high joint strength, while maintaining fusion line width and streamline angle within required standards. At the same time, weld seams must pass flattening and flaring tests without cracking or tearing to avoid inconsistent weld quality or insufficient mechanical performance caused by parameter mismatch.