Production Case Studies
A selection of programs we run every month. Client names withheld under NDA — details shared in a call.
Challenge: Thin-wall Al 7075 frames were warping after machining; ±0.01 mm profile was required across mating faces.
Solution: DFM-driven rib redesign, vacuum workholding, two-stage rough-then-finish machining, CMM check on 100% of critical dimensions.
Result: Scrap fell from 8% to 0.6% · unit cost down 22% · 18 days door-to-door on the first order.
Challenge: Sealed connector housings at 15,000 pcs/month with a zero-leak acceptance spec and tight flatness on the gasket face.
Solution: ADC12 on an 800T machine, full secondary CNC on sealing faces, 100% helium leak test before packing.
Result: Zero leak failures across 12 months of deliveries · landed cost down 17% vs. previous supplier.
Challenge: ±0.02 mm SUS301 terminals at 1.2 million pieces per month with a zero-defect target from day one.
Solution: Progressive die designed and built in-house, 250T press with in-line vision inspection, SPC on critical dimensions.
Result: Six consecutive months with zero quality claims · 12-day replenishment cycle.
Challenge: Surgical-grade 316L parts with Ra 0.4 surface finish and full lot traceability for every shipment.
Solution: Swiss-style turning plus 5-axis milling, electropolishing, lot-tracked material certificates and FAI report per batch.
Result: 100% first-article acceptance · quarterly repeat orders since 2024.
Send drawings and get DFM feedback plus a firm quotation within 24 hours. NDA-friendly, MOQ from 100 pcs.