Case Studies
Aerospace
Application:
Housing for F-16 Targeting Pod
Materials:
Titanium
Overall Dimensions:
16” x 14” x 14”
Challenges:
Assembly consists of six (6) electron beam welded components, which are later machined using angle head attachments with a 5 Axis Machining Center
Aerospace / Military
Application:
Sensor bracket for military/civilian aircraft missile defense system
Materials
2024 aluminum
Overall Dimensions:
8” x 9” x 8”Challenges
Custom tooling for hard to reach areas and 5 axis milling to keep amount of operations and hold critical positioning to a minimum.
Optics / Military
Application:
Lens corrector cell for laser rangefinder
Material:
Titanium
Overall Dimensions:
2.25” Rd x .50” (wall thickness of .03”)
Challenges:
Multiple angled bores, and close tolerance diameters on thin walled titanium. Utilizing Mazak Integrex with turning/milling capabilities (9 axis) produced part in one operation to be able to hold critical bores and positioning.
Aerospace
Application:
Aircraft electronics chassis
Material:
Aluminum and aluminum fin stock
Overall Dimentions:
8.5” x 12” x 29”
Challenges:
Maintaining flatness over entire length of part after assembly by machining in 5 axis mill after final assembly. Assembly consisted of two long sides being assembled with aluminum fin stock and sheet aluminum bonded together on plate machined and ground flat and all four sides assembled with purchased hardware.
Aerospace
Application:
Communications Satellite Component
Material:
7050 aluminum
Overall Dimentions:
8.00 x 9.75 x 13.75
Challenges:
Obtaining material was the first obstacle, then multiple 5 axis milling operations while maintaining close tolerance for both flatness and positioning over several Datum’s and many 3-D and simultaneous 5 axis milling features.
Aerospace / Military
Application:
Tactical Tomahawk Missile
Material:
17-4 Stainless Heat Treated to H1025
Overall Dimentions:
4.25” Rd x 5.00”
Challenges:
Maintaining close tolerance diameters on thin walled stainless in production environment. Developed capability to do Pressure Testing to keep cost down as well as reduce lead time, as well as coordinating outsourcing of Heat Treat, Laser engraving, Mag Particle and Passivate while maintaining traceability to each heat lot of material.
Military
Application:
Future Combat Systems
Material:
A356 Aluminum Casting
Overall Dimentions:
3.00” Rd x 6.00”
Challenges:
Creative fixturing to hold on casting and maintain close tolerance diameters to within .0002 and maintain several close tolerance true positions on thin walled aluminum casting.