The Challenge
Edit this case study in /admin/case-studies. A Tier 1 aerospace OEM needed a titanium structural bracket with compound-angle features that could not be machined on 3-axis equipment. Their existing supplier required 4 setups and consistently missed the ±0.025mm position tolerance.
Our Approach
Our engineering team programmed the part for single-setup 5-axis machining using a custom soft-jaw fixture. We used HSMWorks adaptive clearing to manage chip load in Ti-6Al-4V and ran first article inspection on CMM before scaling production.
The Results
- ±0.012mm position tolerance achieved (2× tighter than spec)
- Cycle time reduced from 47 to 18 minutes per part
- Total lead time: 8 weeks for 5,000 units
- Zero non-conformances over 5,000-piece run