Step ４／６
Sample Production and Test Verification
The Critical Trial from Design to Production
Process Overviews 4 Sample Production and Test Verification
For any B2B custom product, "Sample Prototyping and Testing" yields the first physical result
of the journey from concept to reality. This stage is a crucial test of the design and manufacturing process, and it's essential for risk control and process optimization before scaling up to mass production. Al Forge Tech knows that sample quality builds client trust, which is why we uphold the highest standards throughout the prototyping process, ensuring it is transparent, controllable, and traceable.
A Prototyping Plan: Clear Goals and Processes
（1）Defining the Purpose of the Sample
Different projects and development stages have different sample needs:
| Sample Type | Purpose | Common Scenario |
|
Prototype
|
Early form and fit testing |
Initial design phase, evaluating shape and size |
|
Engineering Sample
|
Validating manufacturability and tolerances |
Entering the process testing phase |
|
PP Sample (Pre-Production)
|
Serving as the benchmark for mass production and quality sign-off |
Submitting to the client for FAI, PPAP |
|
Custom Sample
|
Made according to client-defined parameters and needs |
Special functional testing or demonstration purposes |
We will confirm the sample type and expected results with the client before arranging the corresponding process and resources.
（2）Sample Scheduling and Resource Allocation
Sample production often needs to be slotted into a busy production schedule. To avoid impacting mass production, we will:
- Assign dedicated technicians for sample machining
- Utilize flexible machine time, such as night shifts
- Shorten non-essential waiting times (e.g., expedited surface treatment)
- Pre-schedule a second round of sampling if optimization is needed
From order receipt to sample delivery, we manage the process on a weekly basis and maintain real-time communication with the client.
B Machining Process Trials and Adjustments
（1）Path Simulation and Optimization
Before any metal is cut, our engineering team uses CAM software to simulate the
entire machining path to:
- Calculate tool paths and feed rates
- Simulate risks like interference, material jamming, or vibration
- Preset workpiece reference points and changeover procedures
- Analyze machining time and consumable costs
This significantly reduces the failure rate during physical prototyping.
（2）First-Piece Machining and Parameter Tuning
During the actual trial, we will:
- Install custom fixtures for the sample
- Record the cycle time for each operation
- Fine-tune tool angles, speeds, and feed rates
- Resolve any issues like vibration, deformation, or surface defects
The revised machining parameters will be recorded as the basis for future mass production.
C Surface Treatment and Finishing Confirmation
For aluminum alloy parts, sampling also includes testing the surface treatments, including:
- Confirming the uniformity and thickness of the anodized layer
- Verifying the consistency of sandblasting effects
- Testing the adhesion and scratch resistance of coatings
- Conducting corrosion resistance tests (e.g., salt spray)
- Checking the precision and clarity of laser engraving or marking
If the client has special appearance requirements (e.g., brand colors, mirror finish), we can provide multiple comparison samples for the client to choose the most suitable option.
D Quality Inspection and Validation Documentation
（1）Dimensional Inspection and Reporting
Once a sample is complete, our quality department performs a full dimensional inspection according to the drawings, using equipment such as:
- Zeiss Coordinate Measuring Machine (CMM)
- Surface Roughness Tester
- Height gauges, gauge blocks, pin gauges, thread gauges
- Microscopic analysis equipment (if necessary)
We then provide comprehensive documentation as required by the client, such as:
- First Article Inspection (FAI) Report
- Initial Sample Inspection Report (ISIR)
- PPAP documentation (for automotive applications)
- Material composition certificates, heat treatment reports, etc.
（2）Functional and Application Testing
If the sample has functional requirements (e.g., assembly, load-bearing, pressure
resistance, rotation), we collaborate with the client to arrange:
- Assembly trials
- Dynamic simulations (for rotating parts)
- High/low temperature tests (for aerospace or outdoor parts)
- Special environment simulations (e.g., humidity, salt spray)
We also assist the client in recording test results and providing videos or reports.
E Sample Optimization and Final Approval
（1）Feedback and Revision Cycles
After receiving the sample, the client will conduct their own review and may provide feedback such as:
- Minor dimensional tweak suggestions
- Surface treatment color difference issues
- Assembly compatibility adjustments
- Cost optimization suggestions
We will evaluate the proposed changes and quickly arrange a second trial, typically completing the optimized sample within one to two weeks.
（2）The "Golden Sample" Sign-Off
Once the sample meets all client requirements, both parties sign off on the "Golden Sample," which becomes the official benchmark for all future mass production and quality inspection, including:
- Sealing two identical copies of the sample
- Confirming the drawing and version number
- Locking in the manufacturing process and parameters
- Establishing inspection standards and acceptance criteria
This Golden Sample sign-off paves the way for stable mass production.
Every Sample Is a Promise for Mass Production
For Al Forge Tech, a sample is not just a showcase; it's a dress rehearsal for mass production quality. Through a rigorous prototyping mechanism, comprehensive inspection processes, and rapid adjustment capabilities, we ensure every sample has the potential to be transformed into a stable mass-produced product. While this process is complex, it is the best insurance for ensuring the stable development of a long-term partnership.