Motorcycle crash bar sub-assembly

The production begins with the main frame, mounting brackets, and reinforcement tubes. We utilize CNC bending machines to form the pipes with high accuracy.

All parts are kitted according to the Bill of Materials (BOM). Each component, including bolts and washers, is labeled for assembly. This ensures no part is missing or mismatched before welding begins.

Before assembly, all components are inspected. The inspection include:

• Dimension inspection
• Deburring & surface quality
• Material certifications & grade

We use a custom welding fixtures to ensure each part's location and minimize shape deformation. The process as follows :

• Weld the main frame using TIG Welding for high strength.
• Assemble mounting brackets and reinforcement tubes.
• Stress relief and reshape assembled parts to correct any warping.
• Check dimensions using vernier scale and inspection tools.

After welding, we do sandblasting and powder coating. This chemical treatment improves corrosion resistance and provides a durable, scratch-resistant finish.

We do Incoming Inspection, First Article Inspection, Random Sampling, and In-Process Checks to keep the parts high quality. 100% crash bar will be inspected for weld defects, coating uniformity.

Each crash bar is put into PE film to prevent scratches, then use custom-molded foam. The unit then be placed in a 5-layer corrugated box against damage during global shipping.