Italian auto repair tool manufacturer × Honscn: High-precision gear precision machining solutions help mass production of innovative tools

Technical challenge: Precision tolerance bottlenecks that are difficult to break through with conventional processes

Faced with the "impossible mission" of 0.01mm precision requirements, Honscn's engineering team with 22 years of precision machining experience quickly intervened. Based on the past 100+ successful cases of providing high-precision components for medical devices and aerospace fields, the team keenly identified that the core difficulty of 5 gears lies in the coordinated adaptation of millimeter-level precision: ​

• Differences in material properties: The metal processing characteristics of aluminum 6061-T6 and the plastic molding process of POM need to take into account both strength and wear resistance. Traditional gear machines are difficult to meet the high-precision processing of both materials at the same time; ​
• Tolerance limit requirements: Customers require gear meshing clearance error ≤ 0.01mm, and the tolerance range of conventional processing equipment (usually ≥ 0.05mm) is far from reaching; ​
• Assembly relevance: The matching accuracy of gears and bearings directly affects the operating smoothness of the tool, and "zero error" level dimensional matching must be achieved.

These judgments directly laid the direction for subsequent process innovation - the conventional thinking of "single equipment processing" must be broken.

Innovative solution: Customized process combination breaks through the precision limit

Disruptive process route design

The Honscn engineering team breaks the traditional gear processing logic and proposes a composite process of "CNC lathe precision carving + German customized tooth cleaning cutter finishing":

• CNC lathe base:
  • Using high-precision Swiss imported CNC equipment, customized processing parameters for aluminum 6061-T6 and POM material properties, directly turning out gear blanks close to the finished size, and controlling the initial tolerance within ±0.005mm, laying the foundation for subsequent finishing;
• German customized tooth cleaning cutter precision molding:
  • Joining hands with Germany's top tool manufacturers, we exclusively designed tooth cleaning cutters based on gear module (m=0.8), pressure angle (20°) and material properties. Through 12 passes of progressive milling, we finally achieved a tooth profile accuracy level of ISO 5 (conventional processes only reach level 8), and the meshing clearance error was controlled within 0.008mm.​

 Full-process quality control system​

• First-piece three-coordinate inspection: The first piece of each batch is fully inspected for 21 key dimensions using a German Zeiss three-coordinate measuring machine (CMM) to ensure that the core parameters such as the tooth top circle, tooth root circle, and tooth thickness are 100% in line with the drawings;​
• Assembly simulation test: The processed gears are assembled with the bearings provided by the customer for 100+ simulations, and the measured operating torque fluctuation is ≤3%, far exceeding the industry standard (conventional fluctuation ≤15%).

Cooperation results: From sample delivery to long-term strategic partners​

Quantitative value breakthrough​

• Accuracy compliance rate: The first sample passed the customer inspection at one time, with a 100% pass rate for key dimensions, which is 40% higher than the traditional process;​
• Delivery cycle: It takes only 25 days from solution confirmation to sample delivery, 15 days ahead of customer expectations, which saves valuable time for subsequent tool machine testing;​
• Cost optimization: Through process innovation, while achieving improved accuracy, the single-batch manufacturing cost is reduced by 25% compared with similar processing solutions in Europe and the United States.​

Customer Evaluation and Long-term Cooperation​

"The technical innovation of the Honscn team completely solved our pain points in precision gear processing! From the professionalism of the process plan to the communication efficiency, it has demonstrated the level of a top manufacturing service provider."—— Marco, Director of Customer R&D

At present, both parties have started small-scale trial production (the first batch of 5,000 sets), and the customer has clearly stated that in the future, its high-precision transmission components will be given priority to Honscn.

Industry Inspiration: The "Experience + Innovation" Dual-Wheel Drive of Precision Manufacturing​

This case confirms Honscn's leading position in the field of cross-material precision transmission component processing, and shows how the engineering team transforms technical challenges into business opportunities through the three core capabilities of cross-domain experience transfer, customized technology research and development, and scientific tolerance control. For precision-sensitive industries such as high-end equipment and medical devices, we provide a full-process precision manufacturing solution from "drawing tolerance analysis" to "mass production process verification", and continue to enable the technology implementation of global innovative companies.

Is your project also stuck in the accuracy bottleneck? Click [Contact Us] and let our 22-year-experienced engineering team customize a solution for you!