How the Wooting 60HE v2 Case is made

In a previous update we talked about how sweat testing reshaped our case choices. In short: e-coating finishes, like we used for the Wooting 80HE zinc case, can sometimes react badly to certain skin pH and chemicals, leading to bubbling, and in turn, a damaged case.

For the 60HE v2 we’ve been looking for a finish that looks great and stands against real life use, including coke spills, lotions, and long sweaty gaming sessions.

We ultimately chose the tough (and more expensive) route:

Aluminium extrusion → CNC machining → Anodising

It performed best in both sweat and chemical tests, better than the alternatives we tested.

Here’s how the Wooting 60HE v2 aluminium case is made.

Factory 1: Aluminum Extrusion

The first step of the process is called ‘aluminium extrusion’. It takes a large cylinder of raw aluminium, heats it to roughly 400-500°C to make it soft enough to form, not melt.

A giant press pushes the heated aluminium through a 60HE v2 shaped hole, creating a really long piece of aluminium that’s roughly shaped like the final case.

The metal spaghetti is then stretched to straighten it, cut into manageable lengths, and then put in an oven for about 6 hours to harden and stabilize.

After this, straight, hardened aluminium bars, already close to the case’s outer shape are moved to the CNC factory.

We get straight, hardened aluminum bars already close to the case’s outer shape—perfect feedstock for precision machining.

Factory 2: CNC Machining

Now it’s time to precision-cut the interior and exterior to reach the final shape.

It starts with drilling two holes in the top, then shaping the back side, hollowing out the inside, and CNC-machining the strap attachment features. After that the back side is smoothed so the surface feels clean.

When the CNC part is done, randomly selected cases are checked, both by humans as well as machines. Are the dimensions right? Does the strap attachment fit? Does the surface look good?

If we pass the quality check, we have a fully machined 60HE v2 aluminium case that’s dimensionally checked and cosmetically cleared for finishing.

Factory 3: Anodising

In this final stage we need to create a hard, corrosion resistant oxide layer that locks in colour and protects against sweat and chemicals.

The case is first sandblasted by a 16-jet machine to prep the texture and even out the surface.

It then gets several baths to prepare it for anodization: alkaline, neutralization and acid baths with rinses in between get the surface clean and ready.

After this it’s time to anodise it, by putting the case in an anodising bath for around 30 minutes. This gives the case a hardened oxide layer and imbues colour into the surface.

When that’s done, the case gets checked for surface roughness, reflection and colour with dedicated instruments. Quality control happens in the anodising line, before it leaves the factory, and again on arrival at assembly. Triple verification to make sure the specs for the Bright Silver and Just Black case are met.

The result is a sturdy, long-lasting case with precise fit, solid feel, and a premium look.