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At Aero Industries, we precision machined the housings shown here for use in a medical lift device. We worked in collaboration with the extruder to develop a solution that accommodated the manufacturer’s very tight tolerance and visual requirements. During the initial phases of this project, we all pooled our resources though an extensive revision process to finalize each detail and ensure all requirements were met.
Leveraging our 4-axis machining capabilities, we developed a process that accomplished a range of cutting strategies from one set up. Since the extrusions were large and had a challenging geometry, we proceeded to design and build a customized tooling and fixturing solution. In addition to securely holding the workpiece, the custom fixtures and tooling accounted for minute variations in the extrusion geometry while still allowing us to consistently achieve close dimensional tolerances of ±.004″.
We inspected all of the incoming material to ensure that only conforming parts were fed into the machining cycle. Primary machining operations took place on our vertical mill. By effectively holding and orienting the workpiece and cutting tools, we were able to form the features while creating a blemish-free mill finish. We accomplished this at very rapid cycle times in order to meet project deadlines. Quality assurance consisted of go/no-go gauging as well as dimensional measurement using Vernier-scale tools.
The combination of precision machinery and our technically skilled manufacturing team enabled us to satisfactorily produce housings that were dimensionally accurate with a superior visual appearance. We continue to manufacture them at a rate of 12,000 to 15,000 units/year and turn around orders in two weeks. These quality housings contribute to the safe operation of equipment that supports the important task of transporting disabled and elderly members of the population.
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