Custom Aluminum Foil Prototype Success: How Bradley Precision Machining Partnered with Convill for Small Batch Testing

When James Bradley, Product Development Manager at Bradley Precision Machining (a U.S.-based medical device component manufacturer), needed specialized 0.1mm aluminum foil with micro-perforations for a new diagnostic instrument, they faced two challenges: finding a supplier capable of ultra-thin material processing and offering low MOQ prototype services. After discovering Convill through an industry forum, James initiated contact via our website’s “Request a Sample” form.

Step 1: Technical Consultation (Day 1-3)
Our engineering team scheduled a video call within 24 hours to review his CAD file and performance requirements (tensile strength > 120MPa, tolerance ±0.003mm). We proposed using 1050-H18 alloy with a proprietary punching mold design to achieve 0.08mm holes at 200/inch² density.

Step 2: Sampling & Rapid Tooling (Day 4-10)
A signed NDA and $380 prototype fee secured production. Convill’s workshop completed the custom punch mold in 4 days and delivered 3 rolls of 300mm-wide foil samples via DHL Express. The physical samples included material certification reports.

Step 3: Performance Validation (Day 11-20)
James tested the foils using Convill’s recommended ISO 6892-1 tensile testing parameters. Our team provided real-time support when he observed minor edge curl issues, adjusting annealing parameters for his next batch. The revised samples passed all leak-test benchmarks.

Step 4: Commercial Order & Future Collaboration
Satisfied with the technical responsiveness and ASTM-compliant documentation, Bradley Precision placed an initial 500kg order. James commented: “Convill turned our concept into validated prototypes in 3 weeks without minimum quantity barriers. Their digital workflow eliminated geographic hurdles.”

Ready to test your custom aluminum project? Visit http://www.convill.com/prototype or email prototype@convill.com for a free feasibility analysis within 48 hours.