Custom CNC Machining Case Studies

See how we support customers with reliable machining solutions, practical process control, and stable delivery for prototype and production projects.

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Case Study 1: Aluminum Drone Frame — 5-Axis CNC Machining

• Industry / Application: Robotics & Unmanned Aerial Vehicles (UAV)
• Material + Process: Aluminum 6061-T6, 5-axis CNC machining with camera-aligned setup and multi-axis interpolation
• Lead Time: 14 days for a 6-part prototype set
• Result: ±0.05 mm across critical dimensions

Challenge

The client required ultra-lightweight drone frame components with complex curved geometries and wall thicknesses under 1.5 mm. Standard 3-axis processes would have required multiple setups and introduced alignment risk.

Solution

We used 5-axis simultaneous machining with optimized fixture design to complete the frame set in a single setup while maintaining structural integrity across all load-bearing nodes.

Result

Critical tolerances were achieved, the frames passed a 200-hour cyclic fatigue test with zero failures, and the client moved directly into a 500-unit production order.

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Case Study 2: Medical Device Connector — Precision CNC Parts

• Industry / Application: Medical Devices & Diagnostics Equipment
• Material + Process: Stainless Steel 316L, 4-axis CNC milling and CNC turning
• Lead Time: 18 days for 200 units
• Result: Concentricity held at ±0.005 mm

Challenge

The connector required sub-0.01 mm bore concentricity between the male hub and female receptor. Separate turning and milling operations would have increased re-chucking error.

Solution

We developed a unified soft-jaw holding method to keep the part rigid through all operations on a single machine, then used in-process probing to verify concentricity at each stage.

Result

Surface finish reached Ra 0.4 μm directly from machining, ISO 13485 compatibility requirements were supported, and the full batch shipped with dimensional inspection reports included.

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Case Study 3: Automotive Bracket — High-Volume CNC Production

• Industry / Application: Automotive Structural & Suspension Components
• Material + Process: Aluminum 7075-T6, high-volume CNC milling with 4-axis routines
• Volume: 2,000 units per month
• Result: ±0.08 mm sustained across a 6-month run

Challenge

The customer needed batch consistency without dimensional drift, which meant process stability and tool-wear control mattered as much as raw speed.

Solution

We implemented tool-life capped programs, carbide-grade tool staging, and first-article inspection per shift change to maintain dimensional repeatability across batches.

Result

The project maintained stable tolerances through repeat production, reached a 99.3% on-time delivery rate, and reduced the client’s unit cost compared with their previous supplier.

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Case Study 4: Titanium Aerospace Bracket — 5-Axis Milling

• Industry / Application: Aerospace Structural Fixtures & Mounting Hardware
• Material + Process: Titanium Ti-6Al-4V, 5-axis CNC milling with HSM strategies
• Batch: 10-unit pilot + 50-unit production order
• Result: ±0.03 mm after final stress-relief pass

Challenge

The part featured deep pockets, compound-angle flanges, and thin walls, while titanium increased tool wear and the risk of dimensional creep.

Solution

We used variable-pitch carbide tools, controlled coolant strategy, and an optimized post-heat-treatment machining sequence to reduce distortion and improve surface integrity.

Result

The final parts met tolerance targets, passed dye-penetrant inspection with zero cracks, and were delivered on schedule for aircraft fixture integration.

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Case Study 5: Brass Fitting — CNC Turning & Milling

• Industry / Application: Hydraulic Systems & Pneumatic Instrumentation
• Material + Process: Free-Cutting Brass C360, live-tool lathe with Y-axis capability
• Order Size: 500 units
• Result: Thread fit Class 2 and hex broach within ±0.05 mm

Challenge

The fitting combined external threads, an internal hex feature, and a radial port, making secondary setups risky because they could damage thread integrity.

Solution

We completed turning, threading, hex milling, and radial port drilling in one clamping on a live-tool lathe, eliminating re-grip error and protecting the threaded features.

Result

The project achieved stable thread quality, fast delivery, and a first-pass yield of 99.4%, with parts shipped ready for direct assembly-line use.

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