HTC’s flagship phones have always been known for their excellent build quality and the attention to detail that goes into designing and manufacturing them. Last year’s One X was hailed as a champion of design in the Android ecosystem, but HTC definitely managed to outdo itself with the recently unveiled One.

Unlike other devices clad in a metallic casing, the HTC One does not have large plastic areas to allow the wireless signal to pass through. A metal case acts like a Faraday cage, blocking the radio waves emitted by NFC, wireless, or GPS antennas. So how did HTC’s engineers overcome this problem?

Myriam Joire from Engadget discussed with Scott Croyle, VP for Design at HTC, and the exec shed some light on the process of designing and building the innovative unibody case. Croyle said that some of the antennas inside the HTC One have been machined directly into the aluminum case through a milling process developed in-house specifically for the device.

To achieve the so-called “zero gap” look, HTC applied the plastic bits directly to the aluminum piece, then milled the ensemble down to the final form of the device. The whole process is said to take about 200 minutes for each case, and involves the use of a diamond-tipped tool and an electro-chemical bath.

Check out the promo video to witness a small part of the process and read Engadget’s interview for more insight on how the HTC One came to be.

Bogdan Petrovan

Bogdan is the European Managing Editor of Android Authority. He loves tech, travel, and fantasy. He wishes he had more time for two of those things. Bogdan’s phone is a Nexus 6P.