With over 20 years of experience, Zhuokai has grown from humble beginnings to a leader in the furniture hardware industry. Our success is built on attention to detail and commitment to quality. These principles are why we stand out in the competitive global market, offering products that are a little more expensive, yet of superior value. At Zhuokai, we’ve always been dedicated to "improving quality and offering more reasonable prices," which has helped our clients remain competitive. This dedication is the cornerstone of our growth as a prominent player in the hardware industry.

Having been in the international market for over two decades, Zhuokai hardware products have undergone rigorous processes to transform cold metal into a part of home life. You might wonder what sets our hardware apart from others in this fast-paced global trade market. The answer lies in the advanced and professional production lines—only by experiencing them firsthand can you truly appreciate the outstanding quality.
 

STEP 1: Mold Creation

The mold shapes the metal hardware, and the first crucial step in our manufacturing process is mold development. Our modern mold workshop is equipped with cutting-edge CNC machinery, including drills, milling machines, CNC centers, wire-cutting machines, and EDM machines. These machines operate with high precision, following strict engineering instructions to achieve exceptional accuracy and efficiency.

As the saying goes, "A slight deviation can lead to a huge error." To ensure the precision of the mold, we use a three-axis linked high-end CNC system, keeping tolerance under 0.02mm. After the mold is created, it undergoes manual polishing and repeated testing to eliminate minute errors, ensuring that our molds meet Zhuokai high precision standards.

STEP 2: Stamping

Once the mold is ready, we begin the stamping process. This step is crucial for shaping the hardware into its final form. Stamping is a process that uses a press machine to form metal sheets into the desired shape under pressure. At Zhuokai, we ensure that our stamping process delivers top-notch results with the following advantages:

• Integrated Molding for Enhanced Strength: We use advanced stamping machines that integrate auxiliary equipment for a fully automated process, ensuring high precision and superior product durability.
• Exceptional Efficiency: Our automated and semi-automated stamping systems not only boost production efficiency but also reduce human error, ensuring smooth, long-lasting products.
• Full Automation: The entire stamping process is controlled by a computer, from feeding materials to adjusting settings, ensuring optimal performance without manual intervention.
   

STEP 3: Polishing

Why do Zhuokai sofa legs feel so much smoother and more refined than others, even if the materials are the same? The answer lies in our polishing process. Every product at Zhuokai undergoes five stages of polishing, including robotic sanding and manual finishing. This process enhances the natural metallic shine and gives the product a smooth, refined texture.

Our workers meticulously polish every detail, removing any imperfections, and adding a smooth, soft feel that improves comfort and user experience.

STEP 4: Electroplating

After polishing, Zhuokai hardware products undergo a multi-layer electroplating process. The procedure involves cleaning, activating, copper plating, nickel plating, and finishing with a protective lacquer. This not only enhances the product’s appearance but also improves its resistance to oxidation, wear, and corrosion.

The electroplating process allows each product to take on a unique look, whether it’s a sophisticated matte black, a stunning agate gray, or a luxurious rose gold finish. The process gives every product its own character while providing both aesthetic and functional benefits.

At Zhuokai, our artisans ensure the highest standards by carefully inspecting every product. No scratch, color variation, or imperfection is overlooked, ensuring our reputation for high-quality hardware.
 

STEP 5: Oiling

To further enhance the durability and appearance of our products, we apply a protective oil coating after electroplating. This coating increases surface strength, making our products even more resistant to corrosion and wear. Even under extreme conditions, such as salt spray tests, the products retain their quality and appearance.
 

STEP 6: Quality Control

Every Zhuokai hardware product undergoes five rounds of quality inspection to ensure it meets the highest standards. Our quality control team checks each stage of production to guarantee that every product is free of defects. We go the extra mile to ensure that you get the best, and here’s what each inspection entails:

• Post-Machining Inspection: Even after automated machining, we conduct a thorough manual inspection to catch any potential issues.

• Pre-and-Post-Electroplating Checks: We inspect products before and after electroplating to ensure smoothness and uniformity, checking for any defects or inconsistencies.
• Laboratory Testing: We conduct lifespan tests and salt spray tests to ensure durability and resistance.
• Pre-Assembly Checks: Before assembly, every product is examined for appearance, thickness, and durability to ensure it meets quality standards.
• Final Inspection: Just before shipping, we perform a final check on functionality, packaging, and the accuracy of shipping details.
   

STEP 7: Assembly

The final step in our production process is assembly. Trained technicians follow detailed blueprints and technical requirements to assemble the parts, ensuring that every Zhuokai hardware product is a perfect piece of craftsmanship. From start to finish, we dedicate ourselves to providing top-quality products.

Every Zhuokai sofa leg, no matter how small, undergoes rigorous processes to become a masterpiece. Our focus on detail ensures that every product aligns with our promise to deliver quality and reliability, making your home more beautiful and comfortable.