Case studies
How we solved real manufacturing problems — part geometry, tolerance, material and outcome.
Finned Aluminium Rotor Housing — 38 Fins, 0.9 mm Walls
A finned rotor housing with 38 turned fins and six internal ribs, machined from 6061-T6 billet with 0.9 mm fin walls held to ±0.05 mm across the full 160 mm diameter.
- Material
- Aluminium 6061-T6
- Tolerance
- ±0.05 mm
Sanitary Tri-Clamp Fitting — 316L, Electropolished to Ra 0.4 µm
A 316L sanitary process fitting machined complete on a mill-turn centre, electropolished to Ra 0.4 µm internally and supplied with material certificates and surface finish records.
- Material
- Stainless 316L
- Tolerance
- ±0.02 mm
Robotic Arm Component Set — 14 Parts, Single Supplier, Kitted
A complete set of 14 machined components for a collaborative robot arm, from 7075 structural links to 6061 sensor mounts, delivered anodised, laser-marked and kitted per arm.
- Material
- Aluminium 7075-T651 / 6061-T6
- Tolerance
- ±0.01 mm
Hydraulic Valve Body Family — Cross-Drilled, Deburred, 350 bar Tested
A family of four aluminium valve bodies with intersecting internal passages, deburred internally and pressure-tested to 350 bar before shipment.
- Material
- Aluminium 6061-T6
- Tolerance
- ±0.02 mm
Precision Turned Shafts — Concentricity 0.005 mm TIR
Stepped drive shafts and mounting flanges turned complete on a sub-spindle lathe, holding 0.005 mm concentricity between bearing journals without a grinding operation.
- Material
- Stainless 304 / Steel 1045
- Tolerance
- ±0.008 mm
Aerospace Nozzle Adapter — 5-Axis, AS9102 First Article
A contoured aluminium nozzle adapter machined complete in one 5-axis setup, with an AS9102 first-article report and full traceability to the melt lot.
- Material
- Aluminium 7075-T651
- Tolerance
- ⌀0.02 mm true position
Hardened Gear Set — Ground After Heat Treatment
A set of spur gears and drive components, machined in the annealed condition, case-hardened to 60 HRC and finish-ground to restore geometry lost to heat-treatment distortion.
- Material
- Steel 4140 / case-hardened
- Tolerance
- ±0.002 mm
Stainless Spindle Shaft — Hard Turned to Ra 0.2 µm
A 17-4PH spindle shaft hard-turned to H900 condition, reaching Ra 0.2 µm on the sealing diameter without a grinding operation.
- Material
- Stainless 17-4PH H900
- Tolerance
- ±0.005 mm
Copper Busbar Set — Machined, Plated and Flatness Controlled
Oxygen-free copper busbars for an EV battery pack, machined flat to 0.05 mm over 400 mm, deburred and tin-plated with thickness verified by XRF.
- Material
- Copper C10100 (OFHC)
- Tolerance
- ±0.05 mm, flatness 0.05 mm / 400 mm
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