35% Cost Reduction in Critical Component Production

The Problem

A major aerospace manufacturer was facing escalating costs and extended lead times for precision-machined turbine components. Their existing supplier could not meet the tight tolerances (±0.001mm) required for these critical parts, resulting in high rejection rates and production delays.

Engineering Challenge

The components required 5-axis machining with extremely tight tolerances on exotic materials (Inconel 718 and titanium alloys). The complex geometry and stringent quality requirements made this a high-risk, high-cost production challenge.

Implemented Solution

• Implemented advanced 5-axis CNC machining with real-time monitoring

• Developed custom fixturing to ensure consistent part positioning

• Established statistical process control (SPC) for critical dimensions

• Optimized tooling strategies to extend tool life and reduce cycle time

• Created automated inspection protocols using coordinate measuring machines (CMM)