Heavy-Duty 3-Tier Vehicle Storage Cantilever System Custom Fabrication Case Study

Heavy-Duty 3-Tier Vehicle Storage Cantilever System Custom Fabrication Case Study

1. Client Background & Project Requirements

Our client is a professional end-of-life vehicle dismantling and auto parts recycling company in Phoenix, USA. The company serves local used auto parts remanufacturing and scrap metal recycling businesses.

Its original vehicle yard used flat parking. As a result, the site used land inefficiently and required costly expansion. The client asked DEEPLINK to build heavy-duty vehicle storage cantilever racks. The system stores scrapped vehicles in vertical tiers and increases yard capacity. It also suits the demanding conditions of an outdoor dismantling yard.

Core Client Requirements:

• Product type: 50 sets of heavy-duty vehicle storage cantilever racks for mainstream passenger cars and light commercial vehicles.
• Load rating: Industrial-grade capacity for tiered vehicle storage, forklift handling, and hoisting operations.
• Material specification: Q235B carbon structural steel, thickened section-steel uprights, and high-strength rectangular-tube cantilevers.
• Environmental adaptability: Reliable performance against sun, rain, dust, oil contamination, and outdoor wind loads.
• Surface finish: Outdoor powder coating with RAL5010 Sky Blue uprights and RAL3020 Traffic Red cantilevers.
• Delivery terms: Full production and shipment to the Port of Los Angeles within 45 days, including English instructions and export documents.
• Qualification requirements: ISO9001 certification, a finished-product load test report, and a coating weather-resistance test report.

2. DFM Optimization & Technical Coordination

The client uploaded 3D STEP drawings through the DEEPLINK website. Our engineering team completed a free Design for Manufacturability (DFM) analysis within 24 hours. We then reviewed the outdoor application, vehicle loads, and production volume. Based on this review, we proposed four targeted improvements.

1. Cantilever positioning structure optimization: We used fixture-positioned precision welding for the cantilever structure. Dedicated jigs held the cantilever parts and uprights in the correct position. In addition, back-step welding controlled heat distortion. This process improved dimensional consistency and reduced the risk of offset or slippage during lifting and stacking.
2. Upright base structure upgrade: We formed the main base beam with an integrated CNC bending process. Consequently, the structure distributed loads more evenly and achieved higher torsional strength. The upgraded base also reduced deformation risk under long-term vehicle loads.
3. Hole process optimization: We produced the upright adjustment holes with progressive-die stamping. The process held hole-position accuracy within +/-0.2 mm. Therefore, the racks support flexible tier-height adjustment, and replacement parts remain fully interchangeable.
4. Anti-corrosion detail optimization: We sealed and passivated welded areas to protect coating edges and hard-to-reach weld zones. We then applied a double-layer outdoor powder coating. As a result, the vehicle storage cantilever rack offers stronger corrosion resistance in contaminated dismantling-yard environments.

After the client approved the DFM plan, DEEPLINK produced a full-scale first-article sample within 3 days. The client checked its load capacity, installation accuracy, and coating quality. After successful verification, the client approved mass production.

3. Full-Process Production Implementation

DEEPLINK managed the complete fabrication process, from raw-material preparation to finished vehicle storage cantilever racks. This integrated approach helped us control quality, lead time, and production consistency.

1. Laser cutting: We used 6000W fiber laser cutters for section steel, steel plates, and pipe ends. The parts had smooth edges, and linear tolerance remained within +/-0.1 mm.
2. CNC bending: Our 160-ton CNC press brakes formed the bases and reinforcing plates in one piece. This kept the angle deviation within +/-0.5 degrees and supported stable load distribution.
3. Progressive-die stamping: We stamped adjustment and mounting holes in batches. This method improved both component consistency and production efficiency.
4. Precision welding assembly: Our team used CO2 gas-shielded welding to assemble the main frames. We applied full-length welds at key load-bearing locations. Furthermore, every weld received a visual inspection, while selected welds received ultrasonic testing.
5. Automatic powder coating: After pretreatment, the workpieces entered our automatic electrostatic powder coating line. We applied two layers of outdoor-grade polyester powder and cured the coating in a constant-temperature oven. This created a uniform and durable finish.

Six automated production lines worked together at an overall automation rate of 80%. As a result, DEEPLINK completed all 50 rack sets in 36 days, which was 9 days ahead of schedule.

4. Comprehensive Quality Control System

We followed the ISO9001:2015 quality management system throughout the project. Our quality plan included 39 inspection points from material receipt to final delivery.

• Incoming inspection: We checked material composition, wall thickness, and mechanical properties to confirm that the steel met Q235B requirements.
• In-process inspection: We approved the first article at every stage and sampled each production batch. In addition, we inspected all critical dimensions.
• Finished-product inspection: We verified overall dimensions, welding quality, powder-coating thickness, and coating adhesion.
• Performance verification: We selected three finished rack sets for a 72-hour full-load static test. The measured deflection remained within the allowable range. Moreover, coating samples passed salt spray testing.
• Compliance certification: The finished products meet SGS, RoHS, and REACH requirements. We supplied the complete quality documentation.

5. Surface Treatment & Export Packaging

Outdoor Anti-Corrosion Coating

Outdoor dismantling yards expose storage equipment to moisture, oil, dust, and sunlight. Therefore, we used a three-stage powder-coating system to protect each vehicle storage cantilever rack.

1. First, we sandblasted the structure to Sa2.5 grade. This removed oxide scale and oil residues while improving coating adhesion.
2. Next, we applied an epoxy zinc-rich primer. The primer created a durable anti-corrosion barrier.
3. Finally, we applied outdoor weather-resistant polyester powder. The separate colors for uprights and cantilevers improve identification, while the coating resists UV exposure and oil contamination.

Export Packaging

We also prepared the racks for safe ocean transport and efficient installation at the destination.

• We separated every rack set into uprights, cantilevers, and connecting parts. Bubble wrap protected each component from scratches and impact.
• We sorted and secured the parts on fumigated solid-wood pallets with steel straps. This packaging supports container loading and forklift handling.
• Each pallet included a detailed packing list, an English assembly manual, and a standard accessory kit. Consequently, the client could assemble and commission the system quickly.

6. Delivery & Client Feedback

We shipped all goods from Tianjin Port to the Port of Los Angeles by ocean freight. DEEPLINK tracked each logistics milestone and provided customs documents before arrival. The document set included commercial invoices, packing lists, bills of lading, certificates of origin, and quality certificates. As a result, the client completed customs clearance, on-site assembly, and commissioning smoothly.

 

7. Case Summary

This project demonstrates DEEPLINK’s ability to deliver heavy-duty industrial metal structures for demanding outdoor applications.

• Early technical support: Our free DFM analysis improves product performance, supports site-specific requirements, and reduces total project cost.
• Full-process capability: We manage cutting, stamping, bending, welding, coating, and quality control in-house. Therefore, we maintain stronger control over quality and lead time.
• Reliable quality standards: ISO-based management and performance testing help the system meet operational and compliance requirements.
• One-stop delivery: We support customers from drawing optimization and sampling to mass production and export logistics.
• Responsive service: Our 24-hour technical and after-sales support serves both custom, low-volume projects and larger production programs.

DEEPLINK provides custom metal fabrication solutions for global manufacturing, recycling, and resource-recovery businesses. We combine dependable quality, precise fabrication, and efficient delivery.