Custom Precision Aluminum 5-Axis Machined Parts

XCM CNC machines custom precision aluminum 5-axis parts in Shenzhen, including freeform surfaces, thin blades, angled holes and mounting faces in multiple orientations on impellers, curved housings, gimbal mounts and angled brackets. Complex surfaces are machined to 3D models with surface profile tolerance down to 0.02 mm. Critical surfaces and precision features are machined on imported machining centers from DMG, Matsuura and other manufacturers. Polishing, sandblasting and anodizing are also available.

Aluminum alloys are lightweight and easy to machine, making them suitable for lightweight structures. Electronic housings can also use aluminum’s thermal conductivity. The factory is certified to ISO 9001, ISO 13485, IATF 16949 and GJB9001C. Orders start at one piece. Prototypes typically take 3-7 days and production typically takes 10-15 days, depending on part complexity and quantity.

5-Axis Aluminum Freeform Surface Machining with 0.02 mm Profile Tolerance

Complex freeform aluminum surfaces can achieve a surface profile tolerance of 0.02 mm, evaluated against the 3D CAD model and specified datums. Finish-milled surface regions can achieve Ra 1.6 um, while areas with higher appearance requirements can be polished to Ra 0.2 um. Surface profiles are measured with a Hexagon Inspector Classic 06.08.06 CMM. Complex parts can also undergo 3D scanning or profile inspection.

Aluminum Impeller 5-Axis Machining: 800 mm Diameter and 0.6 mm Blades

Five-axis aluminum impeller machining supports diameters up to 800 mm and blade thicknesses down to 0.6 mm. Blade tips have the lowest stiffness along the blade. Layered cutting and tool orientation adjustments help control chatter and deformation. Blade surfaces are evaluated to a 0.02 mm profile tolerance, and blade thickness and inter-blade passages are inspected with a CMM.

Aluminum Angled Hole and Compound-Angle Face Machining with 0.015 mm Position

Angled holes and spatial mounting faces on aluminum brackets and gimbal mounts are machined using 3+2-axis positioning or simultaneous 5-axis machining. Hole position tolerance is 0.015 mm and perpendicularity is 0.02 mm / 1000 mm. Countersinks have a 90 degree angle with a +/-0.1 degree angular tolerance. A CMM checks hole positions and angled faces against drawing datums. Step heights can be cross-checked with a TRIMOS 600L height gauge.

Aluminum Undercut and Deep-Cavity Machining: 4:1 Aspect Ratio, R1.0 mm Corners

Aluminum housing cavities support a depth-to-width ratio of 4:1, extending to 5:1 with longer tools. For a 40 mm deep cavity, an internal corner radius of at least R1.0 mm is recommended. The minimum internal radius achievable with an end mill is R0.5 mm. Undercuts that remain inaccessible after reorienting the part for 5-axis machining can be made with special tools, multiple setups or EDM. Fully sharp internal corners require EDM or a design change.

Equipment and Quality Systems for Complex Parts

XCM CNC operates DMG 80mono, Matsuura MX-520, Mazak I-100S and Brother machining centers for complex aluminum parts and associated features. Its quality systems include ISO 9001, ISO 13485, IATF 16949 and GJB9001C.

Supporting Operations from Small Connectors to Large Structural Parts

The machining range covers small connectors through large structural parts. Curved parts can include hole machining, threading, edge breaking and necessary secondary operations. Finished surfaces can be polished, sandblasted or anodized, allowing you to source parts that meet both structural and appearance requirements from one supplier.

Tiered Equipment Strategy for Low-Cost CNC Machining, Quality-Assured Production

XCM CNC groups its CNC equipment into four tiers: mainland China, Taiwan, Japan, and Europe and North America. Lower-tolerance operations such as roughing and general hole machining use mainland Chinese or Taiwanese equipment. Surface finishing and precision mating features use imported machines such as DMG and Mazak. Equipment is matched to each part’s actual accuracy requirements, so machines with higher hourly costs are reserved for demanding operations, reducing machining costs while meeting drawing requirements.

Prototype First Article Approval before Production

Five-axis aluminum parts begin with prototypes, typically completed in 3-7 days. A first article inspection (FAI) report is prepared in the customer’s requested format, accompanied by a CMM report and material certificate. Production starts after customer approval. Third-party inspection reports can be arranged separately. An NDA can be signed before quotation for drawings containing confidential designs.

Visible Curved Surfaces Accepted against Color References and Approved Samples

Colors on visible parts such as gimbal housings and electronic enclosures are checked against the customer’s specified color reference numbers. Surface texture, scratches and color variation are assessed against customer appearance standards or a reference sample approved by both parties. Production batches are compared with the same approved sample to reduce appearance variation between batches.