The front panel is made of AISI 304 stainless steel and integrates:

• 4 welded M5x20 studs for wall mounting (a functional choice to prevent tampering and ensure a clean design).
• Additional welded studs for securing the speaker, microphone, and electronic board.
• Light guide.
• Silicone gasket for IP sealing.

The front is finished with acrylic paint that is resistant to industrial detergents, along with screen printing for labeling. The painting process involved two coats:

• The first coat, a white acrylic primer, ensures adhesion to stainless steel.
• The second coat, green in color, aligns with the metro’s visual identity.

The rear shell is also made of AISI 304 stainless steel, laser welded at the four corners to guarantee proper IP sealing.

• Stainless steel processing: precise corner welding and insert application.
• Gasket application: controlled silicone dispensing.
• Painting on smooth surfaces: to ensure adhesion, milled areas were sandblasted to increase surface roughness.
• Adhesive films:
  • Adhesive for light guides, applied to ensure IP65 protection.
  • Removable protective film with low-residue adhesive, effective even in variable temperatures.

• Cross-cut test performed on 1 painted unit from each production batch to verify paint adhesion.
• 100% torque testing of M5 studs to ensure hold.
• Sample torque testing of M3 studs to ensure performance compliance.

As requested by the customer, the product produced has maintained the original dimensions with an improvement in overall weight thanks to the use of aluminium alloy compared to the use of steel in the previous model.

The absorption of the vibrations typical of a rail system. The structure obtained from a solid profile also allowed us to insert transverse ribs to further increase the strength of the structure.unibody product has allowed us to reduce the mechanical fixings with the result of a better.

By using an aluminium alloy, we ensured better heat dissipation compared to the steel previously used. The unibody shell has made it possible to obtain the contact points with the electronic parts directly through chip removal on the rear shell. A single piece able to act as a heat sink instead of the many parts assembled mechanically with screws.

The previous solution used a large number of springs anchored to the rear shell to ensure uniform pressure on the LED board so as to make it equidistant from the glass of the front frame. The use of a fully billet shell has made it possible to considerably reduce the number of springs, resulting in a more rigid and planar structure.

This system consists of 2 different aluminium alloys (5083 and 6082). The result was obtained by using: milling, satin-finishing and surtec chrome plating. By reducing to the 3 machining operations indicated, we have enhanced the product by reducing its complexity, a leaner bill of materials and a guarantee of greater repeatability in the manufacture of the structure..

1. 2 Materials

2. 1 Technology

3. 2 Core processes