CNC Aluminum Machining
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  • CNC Aluminum Machining

CNC Aluminum Machining

WayKen CNC aluminum machining services provide you all-around care that our team will analyze your project carefully and process it with the most efficient process of machined aluminum to optimize your time and cost.

We can help you create aluminum prototypes and custom aluminum parts with our experienced project engineers and machinists to meet your design specification.

If you are seeking a vendor to provide you high quality aluminum parts CNC machined, WayKen is one of the most capable and affordable sources specializing in manufacturing precision machined parts on advanced 3-axis and 5-axis CNC machines.

WayKen’s CNC aluminum service is striving to provide you skillful method and decent quality with a professional team whom analyze your project carefully, figure out the best solution for you and process your custom machined parts in the most efficient way to save your time and cost.

Our metal machining services, especially on aluminum prototyping, custom aluminum machining, aluminum milling, and other than the aluminum parts, we still have other CNC soft metal such as Magnesium, Zinc, Titanium and CNC hard metal such as Steel, Stainless Steel are all our main services.

PROFESSIONAL ALUMINUM MACHINING & EXPERIENCED TEAM

High accuracy required CNC aluminum machining will suggest milling to achieve high tolerance. High speed 3-axis and 5-axis vertical CNC machining centers and our great experience and broad knowledge helps us reach extremely tight tolerances, getting your aluminum parts out on schedule. Our typical tolerance accuracy ranges from +/-0.005" (+/-0.125mm) to +/-0.001" (0.025mm) for CNC aluminum. Our project managers will consult with you on every part of your project and will seek to provide the highest degree of precision possible for efficient precision machining.

We have developed an efficient, accurate and cost-effective process that delivers superior product results. Our design and programming teams review each project not only swift but also accurate to assess the cost, manufacturability and complexity to assure we meet all the specifications of your plan. We analyze your design and accommodate any special needs such as welding, EDM or wire EDM processes required. This in-depth validation ensures you receiving the most effective machining processes for your budget, time and materials.

After the CNC aluminum has been developed, as required, we can also supply secondary processing and typical aluminum surface finishing operations such as sand blasting, shot blasting, polishing, anodizing, oxidation, electrophoresis, chromate, powder coating and painting.

As with other materials, finishes for aluminium are designed to either preserve an existing surface or promote a new one which is visually or functionally more desirable. During the processing, we have been getting in touch with our clients communicating with post finish requirement. Also we always response to all the questions while surface finishing to make sure that will give you the look you want.

5-AXIS CNC MILLING ALUMINUM

WayKen offers advanced 5-axis machining services that significantly increase the range of possibilities for creating parts in various shapes and sizes. 5-axis CNC milling machines can perform high-precision machining and milling of more complex parts that will help you meet your most difficult manufacturing challenges.

We have an experienced team of engineers and machinists capable of performing precision CNC milling jobs using a wide array the latest technology software to write the most effective tool path. We have developed an efficient, accurate and cost effective process to push our machines to their full capabilities that delivers superior results.

Advantages of 5-Axis Machining

On a 5-axis machining center, the cutting tool moves across the X, Y and Z linear axes as well as rotates on the A and B axes to approach the work piece from any direction.

  • Machine on 5 sides of a part with one single setup.
  • Saves set up time, increasing machining productivity.
  • Higher accuracy and outstanding surface finishes, improving overall part quality.
  • Work pieces are not moved through several workstations, reduces error and fixturing costs, less time hand benching.
  • Milling and drilling with compound angles. Improved tool life and cycle time as a result of tilting the tool/table to maintain optimum cutting position and constant chip load.
  • Shorter and more rigid tools may be used. Higher spindle speeds and feed rates may be achieved while reducing the load on the cutting tool.

EDM AND WIRE EDM FOR MACHINED ALUMINUM PARTS

EDM (Electrical Discharge Machining) is used to fulfill the removal of material from the surface of work piece by electrical discharges erosive processes.

It’s widely used in aluminum parts machining as an auxiliary machining process since some complex parts can be achieved only with the help of EDM. Parts which characterized with deep structure are difficult to clear the corners, if only use CNC machining it will leave big radius at the corners, this is not allowed for some cases. By utilizing EDM process it is possible to keep the sharp edge. EDM applications include Blind Cavities (Keyways), Intricate Details, Sharp Corners, Fine Surface Finishes, Thin Walls, and so on.

Wire EDM is a method of cutting metals and other conductive materials, in which a traveling wire disintegrates material in a controlled manner. In wire EDM cutting, a metallic wire (typically made of brass or stratified copper) between 0.1 and 0.3 mm in diameter is used as an electrode which actually arcs with the part to be cut, thereby creating the desired shape or form.

The difference between Sinker EDM and Wire EDM lies greatly in the type of electrode used in each process, the fact that no pre-drilled hole is required with Sinker EDM, as well as the 3D capacities the Sinker EDM is capable of achieving, Wire EDM only has the capabilities to produce 2D parts.

LOW-VOLUME MACHINING FOR CUSTOM ALUMINUM PARTS

Low volume CNC aluminum machining is what we usually do to save your money and time on complex 3D parts compared to production by other methods like casting or molding when the quantities is less than casting but more than prototype. Low volume production runs from WayKen allow manufacturers in automotive, medical or healthcare industry to produce high-quality products at a cheap cost, and thus can deliver products earlier than planned.

Our machining services offer a multitude of capabilities for custom aluminum machining is one of the important and developed businesses from us. Short run production of aluminum machining is the bridge service between prototyping and mass production that we provide.

When the design has been approved we can use the corresponding technology to produce low volume machining quantity required in short time at a reasonable cost. The machines deliver power, speed and accuracy; we design tool geometry, fixture jigs and locating parts as one run to develop to ensure quick setup and consistent dimensions. Our standard of precision reduces secondary hand work and avoids project delays.

ALUMINUM MATERIAL GRADES WE WORK WITH

Aluminum is the most widely used non-ferrous metal. Because of its flexibility and adaptability, as well as its numerous alloys, has a range of industrial uses, including machining and tooling. It’s low cost and formability means that it’s ideal for prototyping, and its particular properties make it popular in all sorts of applications and products. Parts machined from aluminum are often less expensive because they can be machined in less time than many other metals such as steel and do not require additional finishes.

Aluminum comes in many different shapes and grades. The type of aluminum grade you choose ultimately depends on how you intend to use the metal. For details on all available solutions, you might want to read the Wikipedia article on the subject.

CASE STUDY 1: 5-AXIS CNC MILLED ALUMINUM REFLECTOR

Aluminum reflector is widely used in high-end auto models, which is one of the most challenging works in manufacturing a car. In most cases, product designers hope that prototype manufacturers will be able to fully understand and pay attention to all the details they concerned, yet only a few experienced prototype manufacturers can fulfill optic designer’s provision. We can tell by the name that the reflector is an appearance part of a headlamp, which not only plays an optical role, but also determines the appearance of the lamp.

How Do We Process an Aluminum Reflector Prototype?

Rapid prototyping manufacturers often offer a bunch of processing options in regarding particular needs. For instance, we have 3D printing (additive manufacturing), Urethane casting (silicone molds) and rapid tooling for your unique request.

Oftentimes surface roughness has specific requirement, it should be lower than Ra0.2μm and the surface has to be mirror gloss. The normal SLS and other rapid prototyping processes cannot meet the requirements of surface quality. Besides, as an important optical component, reflectors’ precision is forcibly controlled within or below 0.05mm. With regard to machining aluminum reflector, CNC milling is the perfect option, its advantage is embodied in machining the parts with high precision, and the surface of CNC milled parts is high quality.

CNC Milling Process
Part Name : HDLP-Reflector
Machine Tool : 5-axis CNC milling machine
Material : AL-7075-T6
Dimension : 180mm*120mm*100mm
CNC Process : Cutting Tool : Machining Time :
Semi-Finishing R3.0/R2.0/R0.5 30h
Finish-Machining R0.25/R0.15 50h
EDM Process

Taking the complex constructs into account, 5-axis CNC machine is yet to overcome the difficulties when working out the entire part. CNC programming engineers, who gained abundant experience in prototype lamp production, will carry out researches on the feasibility of machining after obtained the drawings of the design.

As for reflector, the significant optic surfaces will be milled by CNC process, but on the rear side, there are critical assemble structure which is hard to be machined by CNC milling since it will leave large radius on the corners. In order to progress, technicians need to make copper electrode and utilize EDM as an auxiliary machining process to help clear the corners. Usually this process will take lots of time.

Post Finish

Now that the work is nearly done, the last step is to work out the post finish. Deburring, polishing, plating, and other handmade post-processing work is notably important, it will directly determine the final appearance.

Regularly, the reflector was asked to be mirror gloss, there are two approaches to realize this effect. One is manual polish, the worker will polish the parts till it is mirror gloss, you should be very careful when polishing the optical surface since some optics need to keep the edges sharp and the polish process may leave radius on the edges.

Another method is by plating, nice milling finish and no impurities is necessary before plating. After all that being conducted, the final surface can be very shiny and beautiful.

CASE STUDY 2: PROTOTYPING ALUMINUM COMPONENTS FOR MEDICAL DEVICE

This is a medical device panel for an Institute of Ultrasonic Instruments who specialize in the product development for Portable Color Doppler. The prototype project is the enclosure of the cloud backup portable ultrasound whose display has the 360 degrees rotation function. It is the innovation and progress for the medical device design of client’s R&D development.

To ensure the light weight and strength for protecting the high-tech electronic components, client had chosen the aluminum machining for the whole prototype model.

The main challenge for this aluminum prototype was the light but strong structure design with one whole part machining. WayKen made the fixture with right position for the quadruple or more surfaces CNC processing. During the rapid prototype process, the fix and assembly is very important as well as the surface treatment. WayKen assembles and polishes before prototype finish ensuring the tight assembly line.

The requirement for the aluminum finishing is painting on the prototype model made it looks as if it is the real parts out as if it is from mass production, not just a normal prototype model. We paint the project according to the pantone No. that client provided with fine texture. We paint it into the front cover matt white color using the alcohol resistant paint. The back cover is with matt black fine texture from Mold-Tech plaque of course in alcohol resistant paint. The handle is in the paint as the back cover and also rubber paint over the black paint to make the handle more like the real hold. High-tech feeling Panel for keyboard is aluminum anodizing to have the feeling of strong.

CASE STUDY 3: CNC ALUMINUM RC CAR PARTS

If you’re a fan of RC cars, then you must know there are many aluminum components in the RC car. Players tend to be keen on off-road race environments such as rock, which not only require extremely high speed, but also have extremely high requirements for the durability of body materials.

It means the higher speed requires the body material to be as light as possible, and the durability requires the material to be strong enough. Aluminum parts are the most widely used components in RC cars, including body, frame and wheel hub and so on.

Due to various ideas to continue to improve the performance of the RC car, the RC car player tend to constantly improve their design, this kind of demand is often minimal quantity, but also need to receive the part in a short time, because the participants did not want to miss a race because of waiting for a parts. WayKen as a prototype manufacturer which is good at providing quick delivery is often the first choice for RC aluminum parts manufacturing, we have rich experience in producing small batch aluminum products, and they can understand and realize the designer's design.

CASE STUDY 4: DRONE / UAV / ROBOT CNC MACHINED COMPONENTS

In the industrial production of UAV/Drone and Robot parts, involves the problem such as material, process, cost, production volume. There are a lot of parts can't be mass production by utilize normal process, so you need to use some special process for small-scale processing accessories, may also involve manual processing link in the middle. In general, we mainly use CNC machining, silicone molding, rapid tooling and other technology to realize custom low volume production. This is a good way to time and cost, speed up product launch cycle.

The aluminum or carbon fiber material as an important part of these components ranges to require the use of high efficiency and high precision CNC machine which work piece in a clamping can complete the whole process, but also equipped with tool library, and has the automatic tool change function. Sometimes it is necessary to realize the linkage control of three or more axes to ensure the machining of the tool with complex surface.

This critical demand is no doubt great challenges for parts manufacturers. When product designer comes to order a few dozen pieces, it’s often hard to respond, which is why production suppliers frequently have to turn to custom machined solutions. Therefore, low volume manufacturing is closely connected with the prototype manufacturer, good manufacturing always have rich and flexible experiences in providing good solutions for the unique requirements.

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