| Name | Detail |
|---|---|
| Product | Metal CNC Machined Parts |
| Material | 6061 Aluminum |
| Order Quatity | 20 pcs |
| Tolerance | 0.01mm |
| Technology | CNC Machining |
| Location | US |
| Application | Industry |
RPS customized a complex-structured CNC-machined part—a precision base for supporting and securing internal components of industrial equipment—for an industrial equipment manufacturer. This part features a unique triangular geometry, incorporating multiple holes and threaded holes of varying sizes, as well as internal cavities designed for weight reduction. Its design requirements are extremely stringent: it not only demands precise dimensional and positional tolerances but also must ensure sufficient structural strength and lightweight properties.
The customer required a base that could perfectly fit the internal space of their equipment and securely mount other precision components. Leveraging our extensive experience in complex geometry machining, we provided the customer with a comprehensive solution ranging from material analysis to multi-axis CNC machining, ensuring the high performance and reliability of the final product.
Manufacturing Challenges & RPS Solutions
Material Selection & Structural Considerations
- Challenge: The part needed to maintain structural strength while achieving lightweight design through internal hollowing, to meet the strict weight control requirements of industrial automation equipment.
- Solution: We selected 6061 aluminum alloy as the material. Renowned for its excellent strength-to-weight ratio, good corrosion resistance, and outstanding machinability, 6061 aluminum alloy is an ideal choice for manufacturing high-performance structural components. Through precision CNC milling, we not only shaped the external contour of the part but, more importantly, successfully machined its internal triangular cavities. This design significantly reduced the overall weight of the part while ensuring structural strength.
Complex Geometry & Multi-Hole Machining
- Challenge: The part contains dozens of holes for mounting and positioning, with extremely tight tolerances for diameter, depth, and center distance. The machining of the part’s inclined surface structure and internal cavities posed significant challenges to processing stability and precision.
- Solution: RPS utilized multi-axis CNC machining centers to complete the machining of most features of the part in a single setup. This approach greatly improved processing efficiency and minimized cumulative errors caused by multiple setups. We precisely controlled the tool path to ensure that the positioning accuracy and perpendicularity of all holes met the customer’s required 0.01mm-level tolerance. Particularly for internal threaded holes, we adopted advanced tapping technology to ensure thread integrity and strength, enabling reliable fastening.
Surface Treatment & Functionality
- Challenge: The part’s surface needed to remain clean, flat, and exhibit a certain level of wear resistance.
- Solution: After the completion of CNC machining, we performed meticulous surface treatment on the part. Through deburring, precision grinding, and cleaning, we ensured that all internal and external surfaces were smooth and flat, with no tool marks or burrs left behind. This not only enhanced the aesthetic appeal of the product but also prevented damage to other precision components during assembly and use.
Outcomes & Value
Through RPS’s precision CNC machining services, we successfully manufactured this high-performance precision base for the customer. With its precise dimensions, lightweight structure, and excellent machining quality, the part perfectly met all the customer’s technical requirements in industrial equipment manufacturing and received high praise from the customer.
This project once again demonstrates RPS’s core competitiveness in handling complex geometric structures and high-precision metal CNC machining. We are capable of providing professional manufacturing solutions based on the customer’s unique designs and accurately translating every detail on the drawings into high-quality physical products.
