Canada Motorsport Engine Manufacturer × Honscn: Precision CNC AL 7075-T6 Engine Parts

Product Overview: CNC Precision Aluminum Engine Component

• Material: AL 7075-T6 high-strength aluminum alloy

• Manufacturing Process: Multi-axis CNC milling

• Application: High-performance racing engine system

• Key Features:

  • Lightweight structure

  • High mechanical strength

  • Complex geometry

This component plays a critical functional role within the racing engine, where weight reduction must be achieved without compromising rigidity or durability.

Project Challenges

1. Complex Geometry and Toolpath Control

The part features:

• Irregular external surfaces

• Deep internal cavities

• Multiple transitions requiring precise toolpath control

Such geometry places high demands on CNC programming strategy, machine stability, and tool selection, especially when machining high-strength aluminum alloys like 7075-T6.

2. Tight Dimensional Tolerances

Several mounting and interface dimensions were defined as critical features. These dimensions had to remain highly consistent to ensure:

• Accurate assembly

• Stable operation under high vibration

• Long-term reliability during racing conditions

Any deviation could affect engine performance or lead to premature wear.

3. High-Quality Logo Engraving

Beyond functional requirements, the customer requested a precisely engraved logo on each part.

This added an additional layer of complexity:

• The engraving had to be clean and sharp

• Positioning and size had to remain consistent across parts

• Surface quality could not be compromised

Our Manufacturing Solution

Engineering Review and Sample Validation

During the prototype stage, our engineering team conducted a detailed analysis of:

• Critical dimensions

• Assembly reference surfaces

• Load-bearing areas

Two prototype parts were produced and underwent multiple rounds of dimensional inspection and assembly verification, ensuring full compatibility with the customer’s engine system.

Optimized Multi-Axis CNC Machining

To handle the complex geometry, we:

• Optimized multi-axis CNC toolpaths for stability

• Controlled cutting parameters to minimize vibration

• Ensured smooth surface finishes on both external contours and internal cavities

This approach allowed us to maintain accuracy while preserving the mechanical properties of the AL 7075-T6 material.

Dedicated Logo Engraving Program

The logo engraving process was treated as a separate machining operation.

By fine-tuning engraving depth, feed rate, and tool selection, we achieved:

• Clear, well-defined lines

• Uniform appearance across parts

• Consistent placement without affecting functional surfaces

Project Results

After completing the initial prototypes:

• Sample quantity: 2 pieces

• The customer conducted full engine installation and track testing

Following successful validation, the customer confirmed a production order of 2,000 units.

The parts were smoothly integrated into the customer’s racing engine programs and approved for long-term supply.

Project Value & Long-Term Impact

This project highlights our capabilities in:

• CNC machining of AL 7075-T6 high-strength aluminum

• Manufacturing of complex, performance-critical engine components

• Stable transition from prototype validation to volume production

By delivering consistent quality and reliable lead times, we earned the customer’s trust and became part of their long-term motorsport supply chain.

Conclusion

High-performance racing engines leave no room for compromise.

Precision machining, material expertise, and process stability are essential—not optional.

At Honscn, we support motorsport and performance automotive customers with engineered CNC solutions designed to perform under the most demanding conditions.

If you are sourcing precision CNC aluminum parts for racing or high-performance automotive applications, we are ready to support your next project.