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Premium Enclosure Manufacturer × Honscn: Precision CNC-Machined Grade 5 Titanium (TC4) Hollow Shells
2025-12-11
Client Background: A Leader in High-End Enclosure Manufacturing
Our client is a specialized manufacturer of premium product enclosures, catering to industries like luxury electronics, medical devices, and high-end consumer goods. Their reputation is built on delivering enclosures that blend exceptional functionality with flawless aesthetics—where even the smallest surface blemish or dimensional deviation can compromise a product’s premium positioning. When they needed a complex hollow tubular shell for a flagship product line, they turned to us after traditional manufacturers failed to meet their strict standards for both shape complexity and surface quality.
Their core demand was clear: a custom hollow tubular enclosure made from Grade 5 Titanium (TC4), featuring intricate cutouts and curves—all while achieving a mirror-like, defect-free surface finish. This wasn’t just a component; it was the “face” of their upcoming product, so compromise was non-negotiable.
Project Overview: Crafting a Titanium Showpiece
The project centered on developing a prototype batch of complex hollow tubular shells for the client’s high-end product line. Unlike standard housings, this component requires precise cutout patterns (to accommodate internal components and ventilation) and smooth curves to capture light and highlight the texture of premium titanium.As the outer casing, its appearance directly influenced the end product’s perceived value—making surface quality and dimensional accuracy critical to the client’s market success.
The client had already approached two other manufacturers, but both struggled with TC4’s inherent machining challenges and the part’s complex geometry. They needed a partner who could marry material expertise with advanced machining capabilities to turn their design into a tangible, flawless product.
The Product: Grade 5 Titanium (TC4) Hollow Tubular Shell
Every aspect of the product was engineered for premium performance and aesthetics:
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Material: Grade 5 Titanium (TC4, Ti-6Al-4V). Selected for its unrivaled combination of high strength (4x stronger than aluminum), corrosion resistance, and premium metallic luster—ideal for high-end enclosures that demand both durability and visual appeal.
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Design & Dimensions: Complex hollow tubular structure with intricate cutouts (varying from 3mm to 8mm in diameter) and contoured external curves. No flat surfaces meant every machining pass required precision control.
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Key Requirements: Surface finish: Ra ≤ 0.4μm (near-mirror smooth, no scratches, burrs, or tool marks)
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Dimensional tolerance: ±0.02mm (critical for fitting internal components)
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Structural integrity: No cracks or micro-defects in hollow sections or cutouts
Market Position: Flagship enclosure for the client’s high-end product line, targeting premium consumers and professional users where design and quality are top priorities.
Core Challenges: Why Traditional Machining Fell Short
The project presented three interlinked challenges that made standard manufacturing methods impractical—each tied to the material’s properties and the design’s complexity:
Challenge 1: Grade 5 Titanium (TC4) Is Inherently Hard to Machine
TC4 titanium has a high tensile strength (up to 1,034 MPa) and low thermal conductivity—meaning heat builds up quickly at the tool-workpiece interface during machining. This causes rapid tool wear, tool chipping, and uneven cuts—issues that become amplified when working with intricate shapes. Traditional lathes or single-axis CNC machines couldn’t maintain consistent cutting parameters, leading to surface defects and dimensional errors.
Challenge 2: Complex Hollow Tubular Design Demands Multi-Axis Control
The shell’s combination of hollow tubing, curved surfaces, and precise cutouts meant no single machining angle could access all features. Traditional 3-axis CNC machines would require multiple setups, introducing alignment errors between features. Even small misalignments (as little as 0.03mm) would ruin the part’s symmetry and fit with internal components.
Challenge 3: Premium Aesthetics Leave No Room for Imperfection
As a visible enclosure, the part needed a flawless surface—free of tool marks, burrs, or discoloration. TC4’s tendency to “grab” cutting tools (causing surface tearing) and heat-induced discoloration made this a major hurdle. Traditional post-processing (like sanding or polishing) risked altering dimensions, so the finish had to be achieved during machining.
Our Tailored Solution: Multi-Axis CNC Machining + Precision Engineering
To overcome these challenges, we combined advanced machining technology, specialized tooling, and strict process control—focusing on “machining perfection” rather than post-processing fixes:
Solution 1: 5-Axis CNC Machining for Complex Geometry
We deployed our high-precision 5-axis CNC machining centers, which offer simultaneous control over all axes. This allowed us to machine the shell’s curved surfaces, hollow core, and cutouts in a single setup—eliminating alignment errors from multiple tool changes. The 5-axis system’s ability to adjust the workpiece angle in real time ensured every feature was accessed with optimal tool orientation, reducing tool wear and improving surface quality.
Solution 2: Specialized Tooling & Cutting Parameters for TC4
To tackle TC4’s machining challenges, we optimized our tooling and process parameters:
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Tool Selection: We used ultra-hard carbide end mills with TiAlN coatings—designed specifically for titanium machining. These tools resist heat and wear, maintaining sharp cutting edges longer than standard tools.
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Cutting Parameters: Our engineers fine-tuned spindle speed (1,500–2,000 RPM) and feed rate (50–80 mm/min) to balance material removal with heat dissipation. We also used a high-pressure coolant system to flush away chips and cool the tool-workpiece interface—preventing heat-induced discoloration and surface tearing.
Solution 3: In-Process Quality Control for Flawless Aesthetics
We integrated quality checks into every stage of machining to ensure perfection:
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Pre-Machining Inspection: TC4 raw material was inspected via ultrasonic testing to detect internal defects that could cause cracking during machining.
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Mid-Process Checks: After roughing (removing 70% of the material) and before finishing, we use a coordinate measuring machine (CMM) to verify the dimensions—adjusting the cutting path as needed to stay within tolerances.
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Surface Finish Monitoring: During the finishing process, we use a portable surface roughness tester to check the Ra value in real time and adjust the tool speed and feed rate to maintain the target value of 0.4μm.
How We Manufactured the Titanium Shells: A Step-by-Step Workflow
Consistency and quality required a structured, traceable process—here’s how we transformed raw TC4 into flawless enclosures:
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Material Preparation: Sourced certified Grade 5 Titanium (TC4) bar stock (Ti-6Al-4V) and cut it into cylindrical blanks. Each blank underwent ultrasonic testing to ensure no internal cracks or impurities.
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Rough Machining: Excess material is removed using a five-axis CNC machine tool to form a basic hollow tubular structure. To ensure dimensional accuracy during the finishing process, we have reserved a "finishing allowance" of 0.1 mm.
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Precision Finishing: Switched to coated carbide finishing tools to machine curves, cutouts, and the internal hollow core. High-pressure coolant was used continuously to maintain surface quality. This step took 2.5 hours per part—slow and precise to avoid defects.
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Deburring & Polishing: Performed manual deburring with diamond-tipped tools (to avoid scratching) and a final precision polishing pass using a buffing wheel with titanium-compatible compound. This brought the surface finish to Ra ≤ 0.4μm without altering dimensions.
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Final Quality Audit: Every prototype underwent a 3-step inspection: Dimensional check with CMM (verifying ±0.02mm tolerance)
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Surface finish test with a profilometer
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Visual inspection under LED lighting (to catch microscopic scratches or blemishes)
Results: Flawless Prototypes & a Commitment to Production
We delivered the prototype batch on schedule—and the client’s reaction was immediate. Their engineering team conducted rigorous testing, including dimensional verification, fit checks with internal components, and surface quality assessments. The prototypes exceeded their expectations:
“These titanium shells are flawless—every curve is precise, the surface is immaculate, and they fit our internal components perfectly. We’ve worked with titanium manufacturers before, but this level of detail stands out as a benchmark in the industry. We’re ready to move forward with production.”— Client’s R&D Director
Buoyed by the prototype success, the client confirmed a trial production order for 100 units, scheduled for January. They’ve also shared plans to expand our partnership to other complex titanium and aluminum enclosures for their 2025 product lineup—turning a prototype project into a long-term collaboration.
Client Value: Beyond a Part—A Competitive Differentiator
Our solution delivered value that extended far beyond a high-quality shell:
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Brand Enhancement: The flawless titanium enclosure elevated the client’s flagship product, strengthening its position in the premium market.
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Time Savings: By delivering production-ready prototypes (no redesigns or reworks needed), we cut the client’s time-to-market by 6 weeks.
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Risk Reduction: Our in-process quality control eliminated the risk of defective parts—critical for a high-cost material like TC4.
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Scalability: Our 5-axis CNC setup is ready to scale from prototypes to high-volume production, ensuring consistency when the client ramps up demand.
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