As a professional manufacturer of outdoor aluminum leisure furniture with over 100 independent design patents, CHOUVANT has established a strict and refined production process for its flagship Cast-Aluminum Series. This process not only ensures the structural stability, weather resistance, and aesthetic appeal of the products but also reflects the brand’s commitment to quality—backed by 4 factory production bases (covering a total area of 180,000 m²) and a team of over 1,000 skilled employees. Below is a detailed breakdown of the production workflow for CHOUVANT’s cast-aluminum furniture. 1. High-Quality Aluminum Alloy Material Selection
The foundation of premium cast-aluminum furniture lies in raw material quality. CHOUVANT exclusively selects high-purity 6061 and 6063 aluminum alloys—materials renowned for their excellent corrosion resistance, high tensile strength, and good castability. These alloys are specifically chosen to withstand harsh outdoor conditions, such as prolonged sun exposure, heavy rain, and high humidity, without rusting or deforming. Before production, all aluminum alloy ingots undergo strict quality testing, including 成分 analysis (composition analysis) and hardness testing, to ensure they meet the brand’s internal standards and international outdoor furniture material requirements. 2. Precision Mold Design and Manufacturing
Molds are the core of cast-aluminum furniture production, directly determining the shape, detail, and consistency of the final products. CHOUVANT’s in-house R&D team (which drives the brand’s 100+ patents) designs each mold based on market demand and aesthetic trends—whether for classic French Bistro Chair frames or intricate tabletop patterns. The mold manufacturing process uses computer numerical control (CNC) machining technology, which achieves an accuracy of up to 0.01 mm. This precision ensures that every cast component has uniform thickness, clear decorative details, and consistent dimensions. After manufacturing, each mold undergoes trial casting and adjustment: the team tests the mold with molten aluminum to check for defects like air bubbles or incomplete filling, and modifies the mold structure until it meets the perfect casting standard. Only then is the mold put into mass production.
3. Melting and Die-Casting
The die-casting step transforms aluminum alloy ingots into preliminary furniture components. First, the selected aluminum alloy ingots are fed into a high-temperature melting furnace, where they are heated to 650–700°C until they melt into a uniform molten state. During melting, a small amount of refining agent is added to remove impurities (such as oxides) from the molten aluminum, ensuring the purity of the material. Next, the molten aluminum is transferred to a die-casting machine under high pressure (ranging from 800–1200 bar). The machine injects the molten aluminum into the preheated precision mold at high speed, filling every corner of the mold cavity. After a short cooling period (usually 30–60 seconds), the mold is opened, and the solidified aluminum component—known as a “casting blank”—is removed. This high-pressure die-casting process ensures that the casting blank has a dense internal structure, no internal cracks, and strong load-bearing capacity, laying a solid foundation for the furniture’s durability.
4. Deburring, Trimming, and Polishing
After die-casting, the casting blank has excess material (such as flash around the mold seams) and small burrs, which need to be removed to improve the product’s appearance and safety. CHOUVANT uses a combination of automated trimming machines and manual polishing to process each component: first, the automated machine cuts off large excess flash, then skilled workers use grinding tools (such as sandpaper and grinding wheels) to smooth out small burrs and uneven surfaces. For components with decorative patterns (e.g., floral engravings on chair backs), the team uses fine polishing tools to enhance the clarity of the patterns without damaging the design details. After this step, the cast-aluminum components have a smooth surface, neat edges, and a preliminary aesthetic finish—ready for subsequent surface treatment.
5. Surface Pretreatment (Degreasing, Pickling, and Phosphating)
To ensure the powder coating adheres firmly to the aluminum surface and improves corrosion resistance, CHOUVANT conducts a strict 3-step surface pretreatment process. First, the components are placed in a degreasing tank filled with environmentally friendly alkaline degreasing agents. Under high temperature (50–60°C), the degreasing agent removes oil stains, dust, and fingerprints from the surface—contaminants that could affect coating adhesion. Second, the components are transferred to a pickling tank containing dilute nitric acid. This step etches the aluminum surface slightly, removing oxide films and creating a rough microtexture, which further enhances the bonding between the aluminum and the coating. Finally, the components undergo phosphating: they are immersed in a phosphating solution, which forms a thin, uniform phosphate film on the surface. This film acts as a barrier against corrosion, preventing the aluminum from reacting with moisture or oxygen in the air. After pretreatment, the components are thoroughly rinsed with pure water and dried in a high-temperature oven (120–150°C) to ensure no moisture remains on the surface.
6. Electrostatic Powder Spraying and Curing
Powder spraying is a key step that determines the color, weather resistance, and lifespan of CHOUVANT’s cast-aluminum furniture. The brand uses high-quality, outdoor-specific polyester powder coatings—available in a variety of colors (to match the Colorful Aluminum Series) and finishes (matte, semi-gloss, or glossy). The spraying process uses electrostatic spraying technology: the powder coating is charged by an electrostatic gun, and the aluminum component (grounded) attracts the charged powder, ensuring the coating adheres evenly to every surface—even hard-to-reach areas like hollow chair legs. After spraying, the components are sent to a curing oven, where they are heated to 180–200°C and baked for 15–20 minutes. During curing, the powder coating melts, flows, and forms a dense, smooth film with a thickness of 60–80 μm. This film has excellent properties: it is resistant to UV radiation (preventing color fading), acid and alkali (resisting rainwater erosion), and impact (withstanding minor collisions). It also gives the furniture a rich, uniform color that maintains its vibrancy for 5–8 years outdoors.
7. Assembly and Component Installation
After the surface treatment is complete, the cast-aluminum components are assembled into finished furniture. CHOUVANT’s assembly line follows strict process standards: for example, when assembling a cast-aluminum dining set, workers first connect the table legs to the tabletop using high-strength stainless steel screws (which are also corrosion-resistant to avoid rust stains). Then, they install additional components, such as armrests for chairs or decorative hardware, ensuring each part is aligned correctly and tightened firmly. For products that require soft elements (e.g., cushions for lounge chairs), the team attaches weather-resistant outdoor cushions (made of water-repellent fabric and quick-drying foam) to the cast-aluminum frames using durable zippers or Velcro. During assembly, each product is checked for stability—for instance, a chair must not wobble when placed on a flat surface—and for aesthetic consistency, such as uniform gap sizes between components.
8. Final Quality Inspection and Packaging
The last step in the production process is a comprehensive quality inspection to ensure every piece of CHOUVANT cast-aluminum furniture meets the highest standards. The inspection covers multiple aspects:
Only products that pass all inspection items are packaged. CHOUVANT uses eco-friendly packaging materials—such as corrugated cardboard boxes and foam inserts—to protect the furniture during transportation. Each package is labeled with product information (model number, size, color) and handling instructions (e.g., “Keep Dry”) to ensure safe delivery to customers worldwide.
From material selection to final inspection, every step of CHOUVANT’s cast-aluminum furniture production process embodies the brand’s pursuit of quality and craftsmanship. This rigorous workflow not only ensures the products meet the diverse needs of scenarios like star-rated hotels, commercial courtyards, and residential gardens but also solidifies CHOUVANT’s reputation as a trusted manufacturer of high-end outdoor aluminum furniture.
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