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US Precision Parts Manufacturer × Honscn Precision: ULTEM 2300 TAN Aerospace-Grade Turned Parts Conquer High-Temperature Machining Challenges

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℃.

US Precision Parts Manufacturer × Honscn Precision: ULTEM 2300 TAN Aerospace-Grade Turned Parts Conquer High-Temperature Machining Challenges 1

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.

US Precision Parts Manufacturer × Honscn Precision: ULTEM 2300 TAN Aerospace-Grade Turned Parts Conquer High-Temperature Machining Challenges 2

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!

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