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Basic overview of metal plating

Electroplating is a process in which a thin layer of other metals or alloys is plated on certain metal surfaces using the principle of electrolysis. The principle is that the gold-plated workpiece is used as the cathode, the electroplated metal is used as the anode (sometimes the metal that is insoluble in the electroplating solution is used as the anode), and the electroplating liquid is the electroplated metal compound and conductive salts, additives, etc. When the poles are connected to the power supply (direct current), the metal ions in the plating solution move to the cathode, where the electrons are obtained, which are reduced and deposited on the cathode surface to become the coating.

Metal plating has a long history of development. The earliest published electroplating literature is the silver plating process proposed by Professor Brugnatelli in Italy in 1805, and later he proposed the gold plating process. By 1840, Elkington, England, applied for the first patent for cyanide plated silver and used it in industrial production, which marked the beginning of the plating industry. In the same year, Jaeobi received the first patent for electroplating copper from an acidic solution.

In the 1840s, electroplating alloys began to appear, such as copper zinc alloy (brass) and precious metal alloy plating. By the 1850s, techniques such as electroplating nickel, copper, tin and zinc were developed one after another. In the early 20th century, people realized the use of acid sulfate galvanizing on the surface of steel strips, Proctor proposed cyanide electrogalvanizing, Fink (C.G. ink) and Eldridge (C.H.Eldridge) proposed the industrial method of chromium plating, and electroplating gradually developed into a complete electrochemical engineering system.

The subsequent two world wars and the growing aviation industry promoted the further development and improvement of electrodeposition, the development of commercial technologies such as electroplating hard chromium and electroplating copper alloy, and electroplating equipment was developed from manual operation to modern fully automated assembly line operation.

Because the alloy coating has better performance than the single metal coating, it has been developed from the initial purpose of obtaining decorative alloy coating to the study of decorative, protective and functional alloy coating. Electroplating After more than 200 years of application and development, new electroplating materials and electroplating process technology methods continue to emerge, and the application field continues to expand. The coating material can be metal, alloy, semiconductor, etc., and the matrix material is also expanded from metal to ceramic and polymer materials.




The process flow of metal plating

Pre-treatment stage

Surface cleaning is an important step in the pretreatment of metal plating. Common methods include chemical cleaning, mechanical cleaning and ultrasonic cleaning. Chemical cleaning removes oil and impurities from surfaces by using specific chemical agents; Mechanical cleaning with the help of grinding, sandblasting and other ways to remove the surface of the oxide layer and dirt; Ultrasonic cleaning uses high-frequency acoustic vibration to enhance the cleaning effect. The purpose of these cleaning methods is to provide a clean surface for subsequent plating processes, ensuring the adhesion and uniformity of the coating.

Pickling is mainly used to remove oxides and rusts from metal surfaces. The common pickling solution includes sulfuric acid, hydrochloric acid, etc. The pickling process can activate the metal surface and improve the binding force between the coating and the substrate.

Pre-plating treatment also includes activation, passivation and other steps. The activation treatment can enhance the activity of the metal surface and make the electroplating process smoother. Passivation treatment forms a protective film on the metal surface to improve the corrosion resistance of the coating.

Electroplating stage

In the electroplating process, the adjustment of parameters such as current and temperature is very important. The current density directly affects the deposition speed and quality of the coating. Low current density leads to slow deposition rate and coarse crystallization of coating. However, too high current density may cause the coating to burn and the surface to be rough. Therefore, it is necessary to select the appropriate current density according to the composition of the bath and the requirements of the coating.

Temperature also has a significant effect on electroplating effect. Increasing the temperature can accelerate the ion diffusion rate and improve the uniformity and density of the coating. However, the high temperature may lead to the decomposition of the composition of the bath and affect the quality of the coating.

The preparation of plating solution is the key to ensure plating quality. Different coating materials require different bath formulations, and the proportion and concentration of various components should be strictly controlled when preparing. At the same time, factors such as the pH and conductivity of the bath should be considered to ensure the stability of the bath and achieve good electroplating results.

Post-processing stage

Cleaning is the first step of post-treatment, which can remove the residual plating solution and impurities on the surface of the coating and prevent the coating from discoloration and corrosion.

Polishing can improve the surface flatness and gloss of the coating and make its appearance more beautiful.

Drying helps to remove moisture from the surface of the coating, preventing water marks and rust.

The sealing treatment forms a dense protective film on the surface of the coating, further improves the corrosion resistance and wear resistance of the coating, and prolongates the service life of the coating. These post-treatment methods cooperate with each other to ensure the quality and performance of the coating.




Advantages and disadvantages of metal plating

Advantages

Metal plating has many significant advantages. First of all, electroplating can greatly enhance the corrosion resistance of metals. By forming a protective coating on the metal surface, it effectively blocks the contact between the metal and oxygen, water and other corrosive substances in the external environment, significantly extending the service life of the metal. For example, the corrosion resistance of galvanized steel products in harsh environments has been greatly improved.

Secondly, electroplating can significantly increase the hardness of the metal. Some coated metals such as chromium and nickel have high hardness, which can improve the wear resistance of the metal after plating on the metal surface, making it more durable in the friction and wear environment.

In addition, electroplating can also improve the electrical conductivity of the metal. For example, gold plating, silver plating and other processes can form a good conductive layer on the metal surface, reduce resistance, and improve current conduction efficiency, which is of great significance in electronic equipment and circuit manufacturing.

In addition, electroplating can also improve the appearance of the metal, making it more smooth, bright, with better decorative, to meet different aesthetic needs.

Disadvantages

However, metal plating also has some shortcomings that cannot be ignored. First of all, the electroplating process will produce serious environmental pollution. Electroplating wastewater usually contains a large number of heavy metal ions, such as chromium, nickel, cadmium, etc., as well as various acid-base substances and organic pollutants. If the waste water is discharged directly without proper treatment, it will cause serious pollution to the soil and water source, endangering the ecological environment and human health.

Secondly, improper treatment during electroplating may have a counterproductive effect. For example, hydrogen embrittlement problems can cause the coating and base metal to become brittle, reducing their mechanical properties. If the post-treatment steps in the plating process are not perfect, it may lead to defects in the coating, affecting its performance and service life.

In addition, electroplating needs to consume a lot of energy and resources, and the process is relatively complex and the cost is high. At the same time, for some small enterprises, there may be a lack of effective pollution control equipment and technology, and it is difficult to meet environmental protection requirements.


Application field of metal plating

Field of protective decoration

In the field of protective decoration, metal plating has a wide range of applications. Sanitary faucets are usually treated with copper/nickel/chromium plating, which not only gives them a bright appearance, but also provides certain protective properties to prevent rust and wear on the faucet surface. Artificial jewelry is also a common application case, such as electroplating imitation gold, gold, silver and other metal coating, or the use of aluminum anodizing process, so that it has a similar color and texture of precious metals, to meet people's needs for beauty and decoration. In addition, hardware with frequent daily contact, such as doorknobs, is often electroplated to enhance beauty and durability.

Field of corrosion protection

In the field of corrosion protection, metal plating plays an important role. Galvanized sheet is a common anticorrosive material, plating a layer of zinc on the iron plate can significantly improve the corrosion resistance of the iron plate, and is widely used in construction, automobile and other industries. Chromium plating is also a common anticorrosive coating, and this process is often used in the wheel rims of old bicycles in the past. In addition, processes such as electroless nickel plating and anodizing can also effectively enhance the corrosion resistance of metals, provide reliable protection for metal products in harsh environments such as industry and outdoor, and extend their service life.

Improved performance areas

In terms of improving performance, metal plating performs well. We know that plastics are originally non-conductive, but under some special requirements, a layer of conductive metal is plated on the surface of plastics through a special process, such as silver or copper plating, which can make plastics have conductive properties, so as to be used in electronic equipment, integrated circuits and other fields. This plating method gives the material new properties and expands its range of applications.

Areas of special performance requirements

For special performance requirements, metal plating can also be met. In the need for wear-resistant occasions, such as the surface of some mechanical parts, a layer of wear-resistant materials can be plated, such as a layer of tungsten carbide or diamond-like carbon (DLC) coating, significantly improve the wear resistance of parts, reduce wear and damage, and extend the service life. In the case of self-lubrication, a layer of graphite nanocomposite coating can be plated on the surface of the material to reduce the friction coefficient, achieve self-lubrication effect, and improve the operating efficiency and stability of the equipment.


The future development trend of metal plating

Market prospect

With the continuous development of the automotive industry, the demand for metal plating will continue to rise. Automotive exterior and interior components, such as bumpers, wheels, dashboards, etc., in order to pursue higher aesthetics and corrosion resistance, there is an increasing demand for high-quality electroplating processes. At the same time, the rise of new energy vehicles, for battery components, electronic components and other protective plating requirements are also more stringent. In the home appliance industry, high-end and intelligent products have become the mainstream, and consumers' requirements for product appearance and durability have prompted home appliance manufacturers to adopt more advanced electroplating technologies, such as nano-plating, to enhance the competitiveness of products. In the field of aerospace, with the advancement of space exploration and the continuous improvement of aircraft performance, higher requirements are put forward for the characteristics of high temperature resistance, wear resistance and corrosion resistance of parts, which will promote the development of metal plating technology to a more refined and high performance direction. It is expected that the demand for metal plating in these industries will continue to maintain a strong growth trend in the future.

Technological innovation

In terms of new electroplating materials, the application of nanomaterials and composite materials is expected to become the focus of research and development. Nano-plating technology will further improve the properties of the coating, such as hardness, wear resistance and corrosion resistance. At the same time, new alloy materials, such as copper alloys with special properties, nickel alloys, etc., will also be developed to meet different industrial needs. In terms of process innovation, intelligent and automated electroplating production lines will become the development trend, which can improve production efficiency, ensure the consistency of product quality, and reduce labor costs. In addition, the development and application of cyanide-free electroplating and low chromium electroplating processes based on green environmental protection concepts will be more extensive to reduce environmental pollution.

Environmental protection and sustainability

In the development process of metal plating, environmental protection and energy saving and emission reduction are crucial. The requirements of the government and society for environmental protection are increasingly strict, and enterprises need to increase investment in environmental protection equipment and technology to ensure that waste water, waste gas and waste residue are discharged up to standard. Research and development and use of more environmentally friendly plating processes, such as plating technology without plating solution emissions, will become the future development direction. At the same time, by optimizing the production process, improve the efficiency of energy utilization, reduce resource consumption, and achieve sustainable development. Strengthening the recycling and reuse of electroplating waste can not only reduce environmental pollution, but also create certain economic value. In short, only by focusing on environmental protection and sustainable development, the metal plating industry can have a broad future.

Understanding the Basics of CNC Machining

CNC machining, or Computer Numerical Control machining, is a manufacturing process that uses pre-programmed computer software to control the movement of machinery and tools. This technology is widely used in the production of machined parts for various industries, including automotive, aerospace, medical, and more. Designing parts for CNC machining requires careful consideration of various factors to ensure optimal results.

Choosing the Right Materials

One of the key considerations in designing parts for CNC machining is choosing the right materials. The material selection will have a significant impact on the performance, cost, and manufacturability of the parts. Common materials used in CNC machining include metals such as aluminum, steel, titanium, and brass, as well as plastics like ABS, acrylic, and nylon. Each material has its unique properties and machining characteristics that must be taken into account during the design process.

When selecting materials for CNC machining, it is essential to consider factors such as mechanical properties, thermal conductivity, corrosion resistance, and cost. For example, if the part requires high strength and durability, steel or titanium may be the best choice. On the other hand, if the part needs to be lightweight and corrosion-resistant, aluminum or certain plastics may be more suitable. Understanding the properties and limitations of different materials will help in making informed decisions during the design phase.

Designing for CNC Machining Considerations

Designing parts for CNC machining involves several considerations to ensure the best possible outcome. These considerations include geometry, tolerances, surface finish, and tool access. Each factor plays a critical role in the manufacturability and performance of the final part.

The geometry of the part is a fundamental aspect of CNC machining. Complex geometries, such as internal channels, tight corners, or thin walls, may present challenges during the machining process. Designing parts with simpler geometries can help reduce machining time and minimize the risk of tool breakage or deflection. Additionally, considering the orientation of the part in relation to the CNC machine and the cutting tools can also impact the overall machining process.

Tolerances are another crucial aspect of designing parts for CNC machining. Tolerances define the allowable deviation from the nominal dimension and are essential for ensuring the part's functionality and fit with other components. It is important to establish realistic tolerances based on the intended use of the part and the capabilities of the CNC machine. Tighter tolerances may require more precise machining operations, which can increase the cost and lead time of the part.

Surface finish is an important consideration for parts that require a high level of precision and aesthetics. The design should account for the desired surface finish and any additional post-machining processes, such as polishing or coating. Proper tool selection and machining parameters are essential for achieving the desired surface finish without compromising the part's dimensional accuracy.

Tool access is a design consideration that directly impacts the machinability of the part. The design should allow for adequate tool access to all features of the part, including internal cavities and filleted edges. Restrictive geometries or limited tool access can pose challenges during the machining process and may require additional setup and tool changes, which can increase costs and lead times.

Optimizing Design for Efficiency and Cost-Effectiveness

Efficiency and cost-effectiveness are critical factors in the design of parts for CNC machining. Optimizing the design to minimize machining time, material waste, and tool wear can result in significant cost savings and improved overall productivity. Several strategies can be employed to achieve these goals.

Designing parts with uniform wall thickness can help reduce material waste and machining time. Varying wall thicknesses can lead to uneven material removal and increased machining complexity. Additionally, incorporating features such as chamfers, fillets, and radii can improve tool efficiency and prolong tool life, ultimately reducing the overall cost of machining.

Another strategy for optimizing design is to minimize the number of setups and fixturing required for machining. Consolidating operations and features onto a single setup can streamline the manufacturing process and reduce the potential for error. Designing parts with standardized features and dimensions can also simplify the machining process and enhance efficiency.

Utilizing standard tooling and cutting parameters can further contribute to efficiency and cost-effectiveness. Standard tooling is readily available and typically more cost-effective than custom tooling. Designing parts with standard tool sizes and specifications can help minimize tooling costs and lead times while ensuring consistent quality and performance.

Utilizing CAD/CAM Software for Design and Programming

Computer-aided design (CAD) and computer-aided manufacturing (CAM) software are essential tools for designing parts for CNC machining. CAD software allows engineers to create detailed 3D models of the part, including precise dimensions, tolerances, and surface finishes. These models can then be used to generate tool paths and machining instructions within the CAM software.

CAD/CAM software enables designers to visualize the part in a virtual environment, identify potential design issues, and make necessary adjustments before the part is manufactured. Additionally, CAM software provides a range of machining strategies and toolpath options that can optimize the machining process for efficiency and quality. From roughing and finishing to toolpath simulation and verification, CAD/CAM software offers comprehensive tools for designing and programming parts for CNC machining.

Using CAD/CAM software also facilitates collaboration between design and manufacturing teams, allowing for seamless communication and data exchange throughout the design and production process. By integrating design and programming within a unified software environment, engineers can streamline the transition from design to manufacturing, reduce errors, and improve overall process efficiency.

Conclusion

Designing parts for CNC machining requires careful consideration of various factors, including material selection, geometry, tolerances, surface finish, tool access, efficiency, and cost-effectiveness. By understanding these considerations and leveraging CAD/CAM software, engineers can optimize the design for manufacturability, quality, and efficiency. With a well-designed and carefully planned approach to CNC machining, manufacturers can achieve superior results while minimizing lead times and production costs. Through continuous improvement in design and technology, CNC machining continues to evolve as a versatile and reliable manufacturing solution for a wide range of industries.

Why Custom CNC Machining Matters in Modern Manufacturing

Industry Shift

The manufacturing landscape is in a state of flux, and CNC custom machining lies at the heart of this transformation. Grand View Research projects that the global CNC machining market will expand at a compound annual growth rate (CAGR) of 8.5% from 2023 to 2030. This growth is predominantly fueled by the escalating demand for small to medium - batch custom production. The era of one - size - fits - all manufacturing is gradually fading, replaced by a more customer - centric approach that caters to the unique needs of diverse industries.

Problem - Solution Framework

The clash between traditional standardized production and the burgeoning demand for customization has become a defining challenge in modern manufacturing. In the medical field, for example, the need for personalized medical implants is a game - changer. Each patient's anatomy is unique, and implants such as hip replacements or dental implants must be custom - made to ensure a perfect fit. Traditional manufacturing methods, which are designed for mass - production of identical items, struggle to meet these exacting requirements. CNC custom machining, on the other hand, offers the flexibility and precision necessary to create implants that match the patient's specific anatomy, enhancing the effectiveness of the treatment and the patient's quality of life.
In the aerospace industry, the pursuit of fuel efficiency has led to a growing demand for lightweight components. These components often need to be custom - made to meet the strict performance and safety criteria of aircraft. For instance, the design of an aircraft's wing components may require complex geometries and the use of advanced materials to achieve the desired weight reduction while maintaining structural integrity. Traditional manufacturing processes may not be able to produce such components with the required precision and consistency. CNC custom machining, with its ability to work with a wide range of materials and produce highly accurate parts, provides a viable solution. It allows aerospace engineers to design and manufacture components that are not only lightweight but also able to withstand the extreme conditions of flight.

The Technological Edge of CNC Custom Machining


Precision Beyond Compare

At the core of CNC custom machining is its unparalleled precision. Computer - controlled machinery can execute complex operations with tolerances that are often within a fraction of a millimeter. This level of precision is unattainable through traditional manual machining methods. For example, in the production of high - end automotive engine components, the slightest deviation in dimensions can lead to reduced engine performance or even engine failure. CNC machining ensures that each component is manufactured to the exact specifications, resulting in engines that are more efficient, reliable, and powerful.

Flexibility in Design

Another significant advantage of CNC custom machining is its flexibility in design. Manufacturers can create components with intricate geometries and complex shapes that would be extremely difficult or impossible to produce using traditional methods. This flexibility allows for greater innovation in product design. For instance, in the development of consumer electronics, the demand for sleek, compact, and feature - rich devices has led to the need for components with unique shapes and sizes. CNC machining enables the production of these components, such as custom - designed heat sinks or precision - cut circuit boards, which are essential for the optimal performance of the final product.

Material Versatility in CNC Machining


Working with a Diverse Range of Materials

CNC custom machining is compatible with a vast array of materials, including metals, plastics, and composites. This material versatility makes it suitable for a wide range of industries. In the manufacturing of industrial machinery, for example, CNC machining can be used to produce components made from high - strength metals such as steel and aluminum. These metals offer excellent durability and mechanical properties, making them ideal for applications that require high - load - bearing capabilities.
In the medical industry, CNC machining can work with biocompatible materials such as titanium and certain types of plastics to create implants and surgical instruments. The ability to machine these materials with precision ensures that the medical devices are safe, effective, and comfortable for patients.

Material Selection Tips

When choosing materials for CNC machining, several factors need to be considered. The mechanical properties of the material, such as its strength, hardness, and ductility, must be compatible with the intended application. For example, if a component needs to withstand high temperatures and mechanical stress, a heat - resistant alloy like Inconel may be a suitable choice.
The machinability of the material is also crucial. Some materials are more difficult to machine than others, and this can affect the production time and cost. For instance, certain types of stainless steel may require special cutting tools and techniques to achieve the desired surface finish and dimensional accuracy.
The cost of the material is another important consideration. While high - performance materials may offer superior properties, they may also be more expensive. Manufacturers need to balance the performance requirements of the component with the cost - effectiveness of the material.

Choosing the Right CNC Machining Partner


Experience and Expertise

When selecting a CNC machining partner, experience matters. A company with a long - standing reputation in the industry is more likely to have the knowledge and skills to handle complex projects. Look for a partner that has worked with a variety of materials and industries, as this indicates their versatility and adaptability. For example, a machining shop that has experience in both aerospace and medical device manufacturing is likely to have a deep understanding of the different quality standards and regulatory requirements associated with these industries.

Quality Assurance

Quality assurance is a non - negotiable aspect of CNC machining. The right partner should have a robust quality control system in place, including the use of advanced measuring equipment and strict inspection procedures. They should be able to provide documentation such as quality control reports and certifications to demonstrate their commitment to quality. For example, a partner that is ISO 9001 certified has met international standards for quality management systems, giving you confidence in the quality of their products.

Capacity and Scalability

Consider the capacity and scalability of the machining partner. If you have a large - scale production project, you need a partner that can handle the volume without compromising on quality. A partner with a modern manufacturing facility and a fleet of advanced CNC machines is more likely to be able to meet your production requirements. Additionally, they should be able to scale up or down their production capacity according to your needs, whether you are in the prototype phase or full - scale production.

Real - World Applications of CNC Custom Machining


Aerospace Industry

In the aerospace industry, CNC custom machining plays a crucial role in the production of aircraft components. From engine parts to structural components, the precision and quality of CNC - machined parts are essential for the safety and performance of the aircraft. For example, the production of turbine blades for jet engines requires the highest level of precision. These blades are subjected to extreme temperatures and mechanical stress during operation, and any deviation from the design specifications can lead to catastrophic failure. CNC machining ensures that the turbine blades are manufactured with the exact dimensions and surface finish required, maximizing their efficiency and durability.

Medical Industry

In the medical field, CNC custom machining is used to create a wide range of products, from surgical instruments to prosthetics. The ability to produce custom - made medical devices that fit the patient's unique anatomy has revolutionized the way healthcare is delivered. For example, custom - made orthopedic implants can provide a better fit and function for patients, reducing the risk of complications and improving the overall outcome of the surgery. CNC machining also allows for the production of complex surgical instruments with precise cutting edges and ergonomic designs, making surgeries more accurate and efficient.

Automotive Industry

In the automotive industry, CNC custom machining is used to produce high - performance components for both traditional and electric vehicles. For example, in the production of electric vehicle (EV) battery packs, CNC - machined components are used to ensure optimal heat dissipation and electrical connection. The precise machining of these components is crucial for the performance and safety of the EV. Additionally, CNC machining is used to create custom - designed parts for high - end sports cars, such as lightweight alloy wheels and precision - engineered engine components, enhancing the vehicle's performance and aesthetics.

Future Trends in CNC Custom Machining


Integration of Industry 4.0 Technologies

The future of CNC custom machining lies in the integration of Industry 4.0 technologies, such as the Internet of Things (IoT), artificial intelligence (AI), and machine learning. These technologies will enable real - time monitoring and control of the machining process, allowing for greater efficiency, quality, and flexibility. For example, IoT - enabled sensors can be installed on CNC machines to collect data on factors such as tool wear, temperature, and vibration. This data can then be analyzed using AI and machine learning algorithms to predict maintenance needs, optimize cutting parameters, and prevent machine failures.

Development of Advanced Materials

As new materials are developed, CNC custom machining will need to adapt to work with these materials. Advanced materials such as nanocomposites and high - strength alloys offer unique properties that can revolutionize product design and performance. CNC machining will play a crucial role in the production of components made from these materials, enabling the realization of innovative product concepts. For example, the development of lightweight, high - strength nanocomposites could lead to the production of more fuel - efficient aircraft and automobiles, and CNC machining will be essential for manufacturing the components required for these new designs.

Conclusion

CNC custom machining has emerged as a game - changing technology in modern manufacturing, offering solutions to the complex challenges posed by the demand for customization, precision, and innovation. With its ability to work with a wide range of materials, produce highly accurate parts, and adapt to the evolving needs of different industries, CNC machining is set to play an even more significant role in the future of manufacturing. By choosing the right CNC machining partner and staying abreast of the latest technological advancements, manufacturers can unlock the full potential of this technology and gain a competitive edge in the global market. If you're looking to embark on a new manufacturing project, don't hesitate to explore the possibilities of CNC custom machining and take advantage of the expertise and insights we've shared in this guide.

Client Background: A US Trade-Manufacturing Enterprise’s Aerospace Precision Needs
Based in Michigan, USA, our client is a leading trade-manufacturing enterprise specializing in precision components for aerospace, medical devices, and other high-end industries. The 2 CNC turned parts in this collaboration are aircraft tubing bearing end caps made from ULTEM 2300 TAN, a high-performance engineering plastic known for its extreme heat resistance (HDT 217℃) and high strength (tensile strength 103MPa). However, its exceptionally high melt viscosity posed significant machining challenges. The client required dimensional tolerances within ±0.02mm and surface roughness Ra≤1.6μm to ensure sealing and structural stability in extreme temperatures ranging from -55℃ to 180℃.



Honscn Precision’s Core Advantages
As a certified leader in China’s aerospace precision machining (ISO 9001:2015, IATF 16949, and AS9100D), we bring over 20 years of expertise in processing high-performance materials like ULTEM and PEEK. Our capabilities include:


100+ high-precision CNC machines, including Mazak Integrex i-100 mill-turn centers and DMG MORI 5-axis machining centers, achieving ultra-tight tolerances as low as ±0.005mm.


Advanced testing equipment: Hexagon Global Performance CMM for 3D dimensional inspection and a -55℃ to 180℃ temperature cycling chamber to validate part stability in extreme environments.



Project Challenges: ULTEM 2300 TAN’s "High-Temperature Deformation Trap"


Dual Challenges of Product Geometry and Material Properties
The two bearing end caps feature precision fit surfaces and thin-walled annular structures, while ULTEM 2300 TAN’s 15,000 Pa·s melt viscosity (10x that of normal ABS) created two critical issues:


Thermal sensitivity: A 5℃ temperature fluctuation changes the material’s linear expansion coefficient by 0.008mm/m, causing uneven wall thickness (initial deviation ±0.3mm vs. target ±0.1mm) and compromising sealing performance.


Residual stress risk: Frictional heat from conventional cutting (up to 80℃) induced internal stress, leading to dimensional shrinkage of 0.05-0.1mm within 24 hours—exceeding the client’s tolerance for bearing fit surfaces.

Hidden Thresholds of Aerospace Standards
As the client emphasized, "End cap deformation could lead to aircraft tubing leaks—a zero-tolerance safety hazard." Beyond dimensional precision, the parts required aerospace material certification (e.g., AMS 3658), a challenge for traditional machining processes to meet alongside material performance requirements.





Suitable products

Solutions: Customized Processes for Two Unique Part Designs
Honscn Precision’s Technical Breakthroughs
1. Aerospace-Grade Machining Environment

Thermostatic workshop & spindle cooling: Maintained a constant 20±1℃ machining environment and equipped the Mazak Integrex i-100 with a spindle cooling system (±0.5℃ control) to minimize thermal impact on material stability.


Liquid nitrogen cooling: For the thin-walled flange structure (Part A), real-time cooling of the cutting zone (30-40℃) via built-in nozzles suppressed material softening, reducing cutting force by 25% and improving surface roughness to Ra≤1.2μm.

2. Parameter Optimization & Layered Machining

Differentiated cutting strategies: For the straight-through structure (Part B), a low-speed (800rpm) + high-feed (0.1mm/rev) strategy with diamond-coated tools (3x tool life) extended machining time by 15% but improved dimensional stability by 60%.


Stepwise stress relief: Three-stage machining (roughing, semi-finishing, finishing) with 30-minute natural cooling intervals between stages eliminated internal stress caused by structural differences, ensuring consistent precision.

3. Material Traceability & Certification Support

Sourced AMS 3658-compliant ULTEM 2300 TAN rod stock directly from SABIC, custom-cut to part-specific dimensions (Part A: 38mm diameter; Part B: 25mm diameter), and provided full material certification (MSDS, physical property reports) for supply chain compliance.



Honscn Precision’s Quality Assurance System

Dynamic dimensional monitoring: Hexagon Global Performance CMM scanned 20 critical dimensions of first articles, achieving 0.008mm roundness on bearing fit surfaces (vs. client requirement ≤0.01mm).


Temperature cycling validation: Parts withstood 3 cycles of 180℃ baking (4 hours) and -55℃ cooling, with dimensional changes controlled within ±0.015mm—far exceeding client expectations.



Project Results: From Trial Success to Strategic Partnership
Key Performance Metrics






Test Parameter



Client Specification



Optimized Result



Key Improvement





Part A Wall Thickness Tolerance



±0.02mm



±0.015mm



85% tighter for thin walls





Part B Bearing Fit Roundness



≤0.01mm



0.008mm



20% better than required





Surface Roughness



Ra≤1.6μm



Ra≤1.2μm



25% smoother than target





Thermal Cycling Dimensional Change



≤±0.03mm



±0.015mm



100% stability in extremes








Client Feedback & Long-Term Collaboration
"Honscn’s team delivered highly specialized solutions for our two end cap designs—they not only solved ULTEM’s deformation issues but also ensured precision consistency across different structures."—David Wilson, Client Quality Manager

Following trial delivery, the client immediately placed a 10,000-piece bulk order (6,000 Part A, 4,000 Part B) and designated Honscn as a core supplier for aerospace-grade engineering plastic components.

Honscn Precision’s Industry Impact
As a benchmark in China’s aerospace precision machining, we empower global high-end manufacturers to overcome the dual challenges of material performance and machining precision through integrated solutions:


Temperature-controlled processes


Material certification support


End-to-end quality testing

From 3-day rapid prototyping to 100,000+ volume production, and from ±0.005mm tolerance control to aerospace-standard certification assistance, Honscn Precision is the trusted partner for Boeing, Airbus, and other aerospace leaders, driving innovation in high-performance component manufacturing.



Start cooperation with aviation-grade precision machining immediately
Whether you are facing the problem of high-performance material processing or need precision parts that meet aviation standards, Honscn Precision can provide you with a full-process solution from material selection to mass production. Click to contact us or visit the official website to communicate your needs with our aviation-grade engineer team and obtain exclusive solutions, so that precision machining is no longer a bottleneck!