Real Parts. Real Challenges.
Real Results.
See how we solve complex CNC machining challenges across industries — from 5-axis aerospace brackets to high-volume connector production.
5-Axis Aerospace Structural Bracket
The Challenge
A European aerospace supplier needed a structural bracket with 23 machined features across 5 faces, including deep pockets, thin walls (1.2mm), and tight positional tolerances. Previous suppliers required 3 separate setups, causing misalignment issues.
Our Solution
We machined the part on our DMG MORI DMU 50 5-axis in a single setup, eliminating setup-induced errors. Thin-wall strategies with trochoidal milling prevented vibration and deflection.
Results
Titanium Surgical Instrument Handle
The Challenge
A US medical device company required a titanium instrument handle with a complex ergonomic profile, internal threading, and a biocompatible surface finish of Ra 0.4. Tight delivery of 2 weeks for first article.
Our Solution
Our mill-turn center handled both the external profiling and internal threading in one operation. Custom fixturing ensured vibration-free titanium cutting. Surface was polished to Ra 0.4 with manual finishing.
Results
EV Motor Housing — Die Cast + CNC
The Challenge
An EV startup needed 2,000 aluminum motor housings machined from die castings. The part required 14 machined features with tight flatness (0.02mm) on sealing surfaces, plus anodizing in custom brand color.
Our Solution
We developed a dedicated 3-op process on 4-axis HMC: Op1 locate & mill seal face, Op2 bore & tap, Op3 mill connector features. Custom anodizing matched the brand color sample provided by the client.
Results
Stainless Steel Hydraulic Manifold
The Challenge
A hydraulic equipment manufacturer needed a 316L manifold with 12 cross-drilled ports and complex internal passages. Port positions required ±0.01mm true position, and all internal edges needed break-free deburring.
Our Solution
We programmed the manifold on a 4-axis VMC with angled fixtures for cross-drilling. Wire EDM was used for the internal cavity profile. All ports were probed on CMM to verify true position before shipment.
Results
Robot Joint Housing — Lightweight Alloy
The Challenge
A robotics company needed a lightweight joint housing with integrated cable routing channels, bearing seats, and mounting flanges. The part required 0.008mm concentricity between bearing bores.
Our Solution
5-axis machining on MAZAK Variaxis with in-process probing to verify bearing seat positions before final bore cuts. Cable channels machined with long-reach tools to avoid secondary EDM.
Results
High-Frequency RF Connector Body
The Challenge
A telecommunications client needed brass connector bodies with 0.005mm bore concentricity and gold plating on internal surfaces. Monthly demand of 10,000 pcs required dedicated production cells.
Our Solution
We set up a dedicated Swiss-type lathe cell with bar feeders for uninterrupted production. Inline gauging checked every 50th part. Gold plating subcontracted to a certified local partner with full thickness testing.
Results
Have a Similar Challenge?
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