For this project, our team completed a custom CNC machining solution for a long-term customer in Germany. The aluminum housing, used in an industrial automation system, required high precision, stable flatness, and consistent cosmetic quality. To ensure the final parts met all functional requirements, we began with a complete DFM drawing analysis, followed by a detailed machining plan.
Drawing Analysis & Key Findings
During the initial review, we identified several manufacturability issues. First, the thin-walled 1.5 mm sections posed a risk of deformation during milling. Additionally, multiple ±0.02 mm tolerance holes required a dedicated finishing process. Moreover, the 120 mm surface flatness requirement (≤0.03 mm) meant we needed to control internal stress during machining. Lastly, sharp internal corners had to be optimized to match CNC tool geometry.
These insights allowed us to propose small design adjustments that improved machinability while fully maintaining the part’s function.
Machining Challenges & Solutions
1. Thin-Wall Deformation Control
To avoid vibration and deformation, we applied multi-step roughing, semi-finishing, and finishing. We also used custom soft jaws and temporary support tabs.
➡ Result: Deflection kept within 0.01–0.015 mm.
2. ±0.02 mm Hole Accuracy
We combined pilot drilling and reaming, operated in a temperature-controlled workshop, and executed 100% CMM inspection.
➡ Result: All hole tolerances met assembly requirements.
3. Flatness on Wide Surface
We applied stress-relief rough machining, rested the parts after roughing, and optimized tool paths for heat control.
➡ Result: Flatness achieved ≤0.02 mm.
4. Cosmetic Surface Finish
To satisfy European quality expectations, we implemented uniform milling patterns, bead blasting, and RoHS-certified clear anodizing.
➡ Result: Consistent aesthetic appearance across batches.
Benefits for the Customer
Through our optimized machining workflow, the customer gained:
-
Higher precision and reliability
-
Improved surface consistency for European markets
-
Faster delivery time due to optimized tool paths
-
Long-term cost reductions (15–20%) through reduced scrap, better fixturing, and efficient batch machining
Why European Companies Choose Us
With extensive experience in Germany, France, Italy, the Netherlands, Sweden, Spain, and the UK, we understand the importance of tight tolerances, stable repeatability, traceability documents, and punctual delivery. Consequently, we provide a dependable solution for CNC machining, aluminum machining, precision machining, and custom parts manufacturing.