Case Studies — Chapter 006

The work, described without naming the customer.

Material, process, equipment, inspection method and the problem that made the part difficult. No customer names, no part numbers, no proprietary geometry.

01 · Aerospace structure

Contoured titanium bracket, four setups reduced to one

A thin-walled structural bracket with compound angles and true-position callouts on both faces. The incumbent process required four setups, and stack-up from re-clamping was consuming the position tolerance.

Material: Ti-6Al-4V
Process: 5-axis milling, single setup, in-process probing
Equipment: Okuma Genos M560V-5AX · Okuma MU-5000V
Inspection: First article on the ZEISS ACCURA with RDS head; in-process CMM sampling by lot
Outcome: One setup, position held to print with margin, and a repeatable process sheet that runs the same way on either machine.

02 · Medical device

Swiss-turned stainless shaft at production volume

A small-diameter shaft with a ground-quality finish requirement, a cross-drilled feature, and full lot traceability on every release.

Material: 303 / 316 stainless
Process: Swiss-type turning with sub-spindle, live tooling, bar-fed lights-out
Equipment: Citizen L20 · Citizen L12
Inspection: Keyence IM image dimension system on first, middle and last of run; certified pin and bore gaging at the machine
Outcome: Finish achieved as-machined without a secondary grinding operation, with an automated inspection report attached to each lot.

03 · Defense subsystem

Turned-and-milled alloy housing with outside processing managed in-house

A housing requiring turning, Y-axis milling, tapped features, laser marking and a plated finish — previously split across three vendors, with schedule slipping at every handoff.

Material: Alloy steel
Process: CNC turning with Y-axis and sub-spindle, secondary milling, laser marking, managed outside finishing
Equipment: DMG MORI NLX 2500SY/700 · Brother Speedio R450 · OMTech Galvo laser marker
Inspection: CMM layout on first article, attribute gaging in process, certificate of conformance with each shipment
Outcome: One purchase order, one traveler, and one supplier accountable for the finished part at the dock.

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The work, described without naming the customer.

Contoured titanium bracket, four setups reduced to one

Swiss-turned stainless shaft at production volume

Turned-and-milled alloy housing with outside processing managed in-house

Have a part with a similar problem?

Have a part in mind? Let's talk.