Case Study

Our client needed a 75 mm diameter motor shaft machined from hardened steel. The shaft had multiple geometric features like steps, grooves, and splines. Conventional manual turning methods resulted in 15% scrap due to form errors.

We utilized CNC turning with in-process gauging to machine the shaft from start to finish in one setup. CNC allowed the machining of complex features not feasible manually. Automated measurements during machining ensured all dimensions stayed within tolerance.

The parts met the target tolerance of ±0.08 mm. Our engineered CNC process reduced scrap to under 3%. Total per-part costs decreased by 25% compared to manual methods. The client was able to meet demands during peak production cycles with faster turnaround.

This case study demonstrates our CNC precision turning expertise in delivering high precision, high productivity solutions to improve quality and costs for complex turned parts. Contact us to know how automated precision turning can benefit your specific application.

Our client needed to mill a lightweight aluminum protective shell with a complex geometry featuring ribs, bosses, and various cut-outs. Manual milling resulted in dimensional inaccuracies up to 0.5mm due to fixture errors. This led to delayed shipments.

Our engineers used 5 axis CNC milling machine to produce the shell from a single billet of aluminum. The CNC machine probed the raw stock and fixtures to map deviations and compensate by adjusting tool paths automatically.

CNC milling enabled cutting complex freeform surfaces not possible manually. The automated process reduced dimensional errors to less than 0.15mm while cutting cycle time by 30% versus manual methods.

The client was able to ship the finished shells faster with significantly improved fit and finish. CNC dynamic tool path compensation minimized scrap losses due to fixturing inconsistencies during machining.

This case study highlights our expertise in multi-axis CNC milling of tight tolerance aerospace and defense parts. Contact us today to discuss how our machining solutions can improve manufacturing productivity and quality for your components.

Our client was manually milling lock panels made of molded plastic, resulting in dimensional variations up to 0.3mm between panels. This caused issues with proper fit and function during the final assembly.

To address the problem, we utilized 3-axis CNC milling to machine the lock panel features like openings, slots, and holes to tighter tolerances. A custom fixturing solution was designed to securely hold each panel for the CNC operation.

The programmable and repeatable nature of CNC milling improved consistency between panels. With manual methods, parts milled on the CNC machine had a tolerance of +/- 0.1mm vs. +/- 0.3mm.

This significantly increased assembly yield rates by over 60% compared to manually milled panels. The customer was able to streamline production by reducing scrap losses and rework.

This case study illustrates how our CNC milling expertise can improve precision, repeatability, and quality to lower manufacturing costs. Contact us today to discuss your component machining needs.