Real CNC Machining Case Studies Across Industries

Case Study Module – Medical Devices

Subheading: Titanium Spinal Implant

Industry: Medical Devices
Material: Ti-6Al-4V Titanium
Part Type: Lumbar Interbody Fusion Cage
Tolerances: ±0.01 mm
Surface Finish: Ra 0.15 μm
Batch Size: 200 pcs

💡 Customer Challenge:
The client required tight tolerances and biocompatible titanium for spinal implants. Previous vendors struggled with microcracks, inconsistent surface finishes, and excessive scrap rates.

🛠 Our Solution: • Custom vacuum fixturing for thin walls
• 5-axis toolpaths with mist cooling
• In-process inspection with Renishaw probing

Subheading: UAV Mounting Bracket

Industry: Aerospace & UAV
Material: 7075-T6 Aluminum
Part Type: Lightweight Mount Bracket
Tolerances: ±0.005 mm
Surface Finish: Ra 0.2 μm
Batch Size: 500 pcs

💡 Customer Challenge:
Required high dimensional accuracy across multiple angled planes; prior vendors caused warping and inconsistent flatness.

🛠 Our Solution: • 5-axis strategy to eliminate reclamping
• Dynamic toolpaths to reduce thermal distortion
• Structural FEM optimization for weight vs strength

Subheading: Smartphone Housing Frame

Industry: Consumer Electronics / 3C
Material: Anodized 6063 Aluminum
Part Type: Smartphone Mid-frame
Tolerances: ±0.01 mm
Surface Finish: Anodized Silver
Batch Size: 5,000 pcs

💡 Customer Challenge:
Ultra-thin wall design (0.7 mm), color uniformity in anodizing, and avoidance of scratch defects during mass production.

🛠 Our Solution: • Vacuum clamping jigs to reduce deformation
• Robotic arms for handling (anti-scratch)
• Controlled anodizing across matched batches

Subheading: Precision Gear Housing for EV Drivetrain

Industry: Automotive
Material: Die-cast Aluminum + Machined Surfaces
Part Type: Transmission Gearbox Housing
Tolerances: ±0.01 mm critical bore
Surface Finish: Machined + Chromate
Batch Size: 1,000 pcs

💡 Customer Challenge:
Tight tolerance in large cast parts led to warping after machining. Alignment of shaft bores required under 10 microns.

🛠 Our Solution: • Used 3-point vacuum fixturing and probing alignment
• Post-machining stress relief bake
• Dual-station horizontal milling for cycle efficiency

Subheading: Stainless Valve Body for High-Pressure System

Industry: Oil & Gas
Material: 316 Stainless Steel
Part Type: High-Pressure Valve Block
Tolerances: ±0.02 mm
Surface Finish: Ra 0.4 μm
Batch Size: 150 pcs

💡 Customer Challenge:
Deep-hole features required burr-free finish and pressure tightness. Conventional drilling caused tool deflection.

🛠 Our Solution: • Deep peck drilling strategy with low-RPM carbide tooling
• Deburring by ECM post-process
• Full NDT pressure test + leak inspection