5-Axis CNC Capacity Upgrade: 20 New Machines Cut Aerospace Parts Production Time by 20%

Honscn is changing that. We already had 50 CNC machines in our facility, and we’ve just invested in 20 new state-of-the-art 5-axis CNC machines—boosting our 5-axis capacity from 20 to 40 units. This transformation has redefined how we produce complex aerospace parts, resulting in a 20% reduction in production lead times for even the most intricate components—without sacrificing an ounce of precision.

In this article, we’ll break down why 5-axis CNC is non-negotiable for aerospace parts, what makes our new machines a game-changer, how the upgrade cuts lead times, and real client stories that prove the difference. Whether you’re an aerospace OEM or a tiered supplier, this upgrade means faster deliveries, lower costs, and more flexibility for your most critical projects.

Why Aerospace Parts Demand 5-Axis CNC Machining (Not 3-Axis)

Before diving into the upgrade, let’s clarify why 5-axis CNC is the gold standard for aerospace parts. It all comes down to complexity and precision—two things the aerospace industry can’t compromise on.

The Limitations of 3-Axis Machining for Aerospace

3-axis CNC machines move along three directions (X, Y, Z) and work best for simple parts like flat brackets or straight shafts. But aerospace parts? They’re rarely simple. Imagine a sensor housing with a curved exterior, a slanted mounting hole, and a recessed interior—3-axis machines can’t handle this in one setup.

Here’s the problem with 3-axis for aerospace:

• Multiple setups: You have to reposition the part 2–3 times to machine all features. Each setup adds time (1–2 hours per setup) and introduces error—even a tiny misalignment (0.001mm) can make the part unusable.

• Tool reach issues: 3-axis tools can’t reach deep or angled features without colliding with the part, forcing you to use longer (and less stable) tools that compromise precision.

• Slow cycle times: Machining one feature at a time means longer production runs—great for simple parts, but a disaster for tight aerospace deadlines.

A tier 2 aerospace supplier once came to us with a problem: They were using 3-axis machines to make engine brackets, and each bracket required 3 setups (6 hours total). Their lead time was 12 weeks, and 8% of parts were scrapped due to setup errors. We switched them to our existing 5-axis machines—setup time dropped to 1 hour, lead time to 8 weeks, and scrap rate to 1%.

The 5-Axis Advantage: One Setup, Perfect Precision

5-axis CNC machines add two rotational axes (A and B) to the standard X/Y/Z, meaning the part can rotate while the tool cuts. This lets us machine complex features in one setup—no repositioning, no errors, no wasted time.

For aerospace parts, this translates to:

• Tighter tolerances: One setup eliminates alignment errors, so we hit ±0.005mm tolerances consistently (critical for parts that fit into jet engines or avionics systems).

• Faster cycle times: Machining all features at once cuts production time per part by 30–40% vs. 3-axis.

• Better surface finishes: The tool approaches the part from optimal angles, reducing tool marks and eliminating the need for post-processing (like sanding or polishing).

It’s not just about speed—it’s about reliability. Aerospace parts have zero room for error; 5-axis machining ensures every part is identical, batch after batch.

Honscn’s 5-Axis Upgrade: 20 New Machines, Game-Changing Technology

Our latest capacity upgrade isn’t just about adding more machines—it’s about adding the right machines to complement our existing 50 CNC units. We handpicked 20 high-performance 5-axis CNC mills from industry leaders like DMG MORI and Haas, each built to tackle aerospace’s toughest challenges. Here’s what makes these machines stand out:

The Machines: Built for Aerospace’s Toughest Jobs

We didn’t cut corners—each new machine is loaded with features that matter for complex parts:

• High-speed spindles (20,000 RPM): Cut through tough aerospace materials (titanium, Inconel, 7075 aluminum) faster without overheating. For example, machining a titanium engine bracket used to take 45 minutes; now it takes 35 minutes.

• Advanced tool changers (60+ tools): Swap tools automatically, so we can machine multiple features (holes, slots, curves) without manual intervention. This cuts downtime per part by 15%.

• In-line probing systems: Sensors check the part’s dimensions while it’s being machined, adjusting the tool path in real time if something’s off. This eliminates “guesswork” and keeps scrap rates below 1%.

• High-efficiency design: All 20 machines feature optimized tool paths and rapid traverse rates, minimizing non-cutting time. A 1,000-unit batch that used to take 2 weeks now takes 10 days.

Why 20 Machines? Solving the Capacity Bottleneck

Before the upgrade, our 50 CNC machines included 20 5-axis units—enough for small to medium batches, but not for large-scale aerospace projects. Clients with 5,000+ unit orders often had to wait 10–12 weeks for delivery, as we juggled their jobs with smaller orders.

Adding 20 more machines means:

• No more waiting: We now have 40 5-axis machines dedicated to aerospace parts, so even large batches get prioritized. Lead times for 1,000+ units are down from 10 weeks to 8 weeks (a 20% cut).

• Flexibility for custom parts: We can handle both high-volume production (10,000+ units) and small-batch custom jobs (50–100 units) without bottlenecks. A client needing 200 custom sensor housings for a prototype can get them in 5 days, while a 5,000-unit production run for engine brackets takes 7 days.

• Redundancy: If one machine needs maintenance, we have 39 others to keep production on track. No more delays due to equipment downtime.

The Numbers: How the Upgrade Translates to Value

Let’s put the upgrade into hard numbers—for a typical aerospace part (a titanium engine bracket with 8 features, ±0.005mm tolerance):

These numbers aren’t just impressive—they’re transformative for aerospace manufacturers. Shorter lead times mean faster product launches, lower inventory costs, and the ability to respond to last-minute orders (a common request in the industry).

How the Upgrade Cuts Lead Times by 20% (3 Key Drivers)

A 20% reduction in lead time doesn’t happen by accident—it’s the result of three interconnected improvements from the 5-axis upgrade:

1. Fewer Setups = Less Downtime

As we mentioned earlier, 5-axis machining eliminates multiple setups. But with 40 machines, we can go a step further: We dedicate specific machines to specific part families. For example, 10 machines handle titanium engine brackets, 8 handle aluminum sensor housings, and 12 handle Inconel avionics components.

This means:

• No tooling changes between batches: If we’re making 5,000 titanium brackets, we keep the tooling loaded on 10 machines, so we can run the batch 24/7 without stopping to swap tools.

• Faster changeovers for new parts: Even when switching to a new part, we have dedicated machines with standard tooling, so setup time is cut from 4 hours to 1 hour.

A client making avionics housings saw their lead time drop from 9 weeks to 7 weeks—all because we dedicated 8 machines to their part, eliminating setup delays.

2. Material Expertise + Machine Power = Faster Cuts

Aerospace materials are tough—titanium is 4x stronger than steel, and Inconel can withstand temperatures up to 1,200°C (2,192°F). Machining these materials slowly is easy, but machining them fast without ruining the part takes expertise.

Our team has 15+ years of experience machining aerospace materials, and we’ve optimized the new 5-axis machines to handle them efficiently:

• Custom cutting parameters: We’ve programmed each machine with material-specific speeds and feeds (e.g., 15,000 RPM for titanium, 20,000 RPM for aluminum) that balance speed and precision.

• Coolant systems: High-pressure coolant (1,000 PSI) keeps tools and parts cool, preventing overheating and extending tool life. This lets us run longer without tool changes.

• Strategic material sourcing: We keep ample stock of common aerospace-grade materials (aluminum 7075, standard stainless steel) to start production immediately. For special materials like titanium and Inconel, we have long-term partnerships with trusted suppliers who can deliver within 48 hours—no production delays.

A client needed 500 Inconel exhaust components. Their previous supplier took 12 weeks to deliver (due to slow machining and material delays). We had Inconel in stock, used our new 5-axis machines with custom cutting parameters, and delivered the 500 components in 8 weeks—20% faster.

Client Stories: How the 5-Axis Upgrade Transformed Their Projects

Let’s look at two real clients who benefited from our 5-axis capacity upgrade—one needing high-volume production, the other small-batch custom parts.

Story 1: Aerospace OEM (High-Volume Engine Brackets)

A U.S.-based aerospace OEM needed 10,000 titanium engine brackets for their latest jet model. The brackets had 12 features (holes, curves, slots) and required ±0.005mm tolerance.

The Problem Before Upgrade:

• Their previous supplier used 3-axis machines, with a lead time of 16 weeks.

• 10% of parts were scrapped due to setup errors.

• They were struggling to meet their jet’s launch deadline—they needed the brackets in 12 weeks.

Honscn’s Solution (With New 5-Axis Machines):

• We dedicated 15 of our new 5-axis machines to the project, enabling parallel processing that accelerated production.

• We used custom cutting parameters for titanium (15,000 RPM, high-pressure coolant) to cut each bracket in 35 minutes (vs. 45 minutes with old machines).

• In-line probing systems checked every bracket, ensuring zero defects.

Results:

• Delivered 10,000 brackets in 10 weeks—2 weeks ahead of their deadline.

• Scrap rate was 0.5% (only 50 parts rejected, vs. 1,000 with their old supplier).

• They saved 200,000 in penalties).

Story 2: Tier 3 Supplier (Small-Batch Custom Sensor Housings)

A European tier 3 supplier needed 200 custom aluminum sensor housings for a satellite project. The housings had a curved exterior, a slanted mounting hole, and a recessed interior—all requiring ±0.003mm tolerance.

The Problem Before Upgrade:

• They’d hired a shop with only 5 5-axis machines, which were booked solid. Their lead time was 8 weeks.

• They needed the housings in 6 weeks to meet their satellite integration deadline.

Honscn’s Solution (With New 5-Axis Machines):

• We had 25 5-axis machines available, so we dedicated 2 machines to the project (no waiting for capacity).

• We machined all features in one setup, cutting production time per housing from 40 minutes to 30 minutes.

• We used our in-stock 7075 aluminum (aerospace-grade) to start production within 24 hours of receiving the design.

Results:

• Delivered 200 sensor housings in 5 weeks—1 week ahead of their deadline.

• All 200 housings passed the satellite manufacturer’s tolerance checks (zero rejections).

• The supplier now uses us for all their custom 5-axis work—they’ve placed 3 more orders in the past 6 months.

Honscn’s Differentiator: It’s Not Just Machines—It’s the Total Package

Adding 20 5-axis machines is a big investment, but what sets Honscn apart is how we combine this capacity with expertise, service, and quality control. Here’s why aerospace clients choose us over other shops:

1. Aerospace-Certified Quality Control

Aerospace parts require strict certifications (AS9100, ISO 9001), and our quality control process is built to meet them:

• 100% inspection: Every part goes through three checks: in-line probing during machining, post-machining laser scanning, and manual inspection with calipers (for critical features).

• Traceability: Every part is linked to its material batch, machine, and operator—so you can track its entire production history (required for aerospace audits).

• Certified materials: We only use aerospace-grade materials with mill certificates (MTCs), so you know the material meets ASTM standards.

2. A Team of CNC Machining Pros with 20 Years of Experience

Our CNC programmers and operators bring an average of 20 years of industry experience—we’re not just machine operators, but machining specialists who understand the nuances of complex part production. They know how to maximize efficiency while maintaining precision, and they’re deeply familiar with the unique demands of aerospace components.

• They can optimize your design for 5-axis machining (e.g., adding fillets to reduce tool wear, adjusting tolerances to avoid over-specification).

• They’re well-versed in aerospace regulations (FAA, EASA) and can help you navigate compliance requirements for critical components.

• They’re available 24/7 for urgent questions—if you need to adjust a design mid-production, we can make changes within 4 hours.

3. Transparent Communication & Timelines

Aerospace projects live or die by deadlines, so we keep you in the loop every step of the way:

• Real-time production tracking: You get access to a cloud dashboard where you can see how many parts have been made, how many are in inspection, and when the batch will be done.

• Weekly updates: Our account managers send you a short email with progress reports, photos of parts, and any potential issues (we solve most before they affect the timeline).

• No surprise delays: We build buffer time into every quote, so even if there’s a minor issue (like a tool breakage), we still meet your deadline.

Future Capacity: What’s Next for Honscn’s 5-Axis Machining

This upgrade is just the start. We’re committed to staying ahead of aerospace’s growing demand for complex parts, and we have two big plans for 2024–2025:

• Add 15 more 5-axis machines: We’ll focus on larger machines (for parts up to 1m x 1m) to handle bigger aerospace components like wing spars and fuselage sections, growing our total CNC fleet to 85 units.

• Integrate AI-powered programming: AI will optimize tool paths automatically, cutting production time by another 10–15% and reducing tool wear—building on our 20 years of machining expertise with cutting-edge tech.

Our goal is simple: To be the go-to 5-axis CNC supplier for aerospace manufacturers, offering the fastest lead times, highest precision, and most reliable service in the industry.

Conclusion: Faster, Precise, Reliable—The New Standard for Aerospace Parts

The aerospace industry can’t afford to wait for slow, error-prone production. Honscn’s 5-axis CNC capacity upgrade—20 new machines, 24/7 automation, and aerospace expertise—cuts lead times by 20% and sets a new standard for complex part production.

Whether you need 100 custom sensor housings or 10,000 engine brackets, our 40 5-axis machines can handle it—on time, on budget, and with zero defects. We’re not just a supplier; we’re a partner in your success, helping you meet deadlines, reduce costs, and launch better aerospace products.

Ready to experience the difference? Send us your part design (even a sketch) and tell us your deadline. We’ll give you a free quote, a detailed production timeline, and a sample part (if you need it) to prove our precision. Let’s build the future of aerospace—faster than ever before.