Manufacturing Case Studies

Customer Requirement

The customer needed a lightweight aluminum headlight housing with cosmetic precision and stable sealing surfaces for a new EV platform.

Challenges

• Thin wall sections risked distortion during machining.
• Visible surfaces required a clean finish with no tool marks.
• The launch program needed prototype approval in under one week.

Solution

We optimized the fixture strategy, adjusted machining order for thin-wall stability, and synchronized finishing inspection with the prototype schedule.

Process & Material

5-axis CNC machining + secondary finishing

AL6061-T6

Customer Requirement

A telecom customer required compact connector enclosures with tight mating features and clean anodized surfaces.

Challenges

• Small features increased tool access complexity.
• Thermal performance could not be compromised by cosmetic changes.
• The buyer needed one supplier for prototype and production transition.

Solution

We revised the process route, improved heat-dissipation geometry during DFM review, and delivered production-aligned prototypes.

Process & Material

Precision CNC machining + anodizing

AL6063

Customer Requirement

An automation integrator needed durable precision fixture blocks for repeat assembly alignment inside a new production cell.

Challenges

• Concentricity and flatness both affected final assembly accuracy.
• The part had to withstand repeated industrial handling.
• The project had a narrow installation window.

Solution

We split roughing and finishing into separate setups, introduced interim inspection gates, and stabilized the assembly datum strategy.

Process & Material

CNC machining + grinding

42CrMo steel

Customer Requirement

A UAV startup needed lightweight shell components for repeated test cycles with quick revision turns.

Challenges

• Thin-wall geometry was vulnerable to deformation.
• Frequent design updates required a flexible prototype path.
• Critical mating features still needed precision tolerance control.

Solution

We paired rapid prototyping with CNC finishing for critical features, then moved approved revisions into a scalable machining workflow.

Process & Material

Rapid prototyping + CNC finishing

AL7075 + engineering resin prototypes