Case Studies
Proven engineering solutions from automotive, aerospace, electronics, and medical industries — showcasing precision fixture design, deformation control, and efficiency optimization
Automotive Steering Housing Machining Fixture
Challenge
A tier-1 automotive supplier needed a custom 5-axis fixture for machining complex aluminum engine blocks. The fixture had to maintain ±0.01mm tolerance across 50+ datum features while providing access for all machining operations in a single setup.
Solution
We designed a modular fixture system with hydraulic clamping and precision locating pins. The fixture incorporated:
- 6061-T6 aluminum base plate with hard anodizing
- Hardened steel locating pins (HRC 58-62)
- Hydraulic clamps with adjustable force control
- Integrated chip evacuation channels
Results
65%
Setup Time Reduction
±0.008mm
Achieved Tolerance
50K+
Cycles Completed
Thin-Walled Aluminum Plate Milling Clamping Strategy
Challenge
An aerospace manufacturer required a fixture for machining thin-walled titanium wing ribs without causing deformation. The parts had complex 3D geometry and required ±0.005mm tolerance with AS9100 documentation.
Solution
Our engineering team designed a vacuum-assisted fixture with soft contact points:
- Vacuum workholding to minimize clamping force
- Adjustable soft contact pads for complex geometry
- 7075-T6 aluminum fixture body
- Full FEA analysis for deformation prediction
- Complete material traceability and certs
Results
Zero
Part Deformation
±0.005mm
Achieved Tolerance
100%
First Pass Yield
Axial Clamping Fixture Design for Thin-Walled Tubular Parts
Challenge
An electric vehicle manufacturer needed a high-precision assembly jig for positioning 96 cylindrical battery cells with ±0.1mm positional accuracy. The jig had to integrate with automated welding equipment and ensure proper cell alignment throughout the assembly process.
Solution
We developed a modular assembly fixture with precision cell locators:
- Laser-cut cell positioning template (±0.05mm)
- Quick-release clamping mechanism
- Integrated thermal insulation
- Anti-static aluminum construction
- Indexing features for robotic handling
Results
40%
Faster Assembly
±0.08mm
Cell Positioning
99.8%
Assembly Quality
Hydraulic Rotary Fixture: Optimizing Gearbox Housing Machining on VMC
Challenge
A medical device manufacturer required a CMM inspection fixture for titanium orthopedic implants with complex freeform surfaces. The fixture needed to be cleanroom-compatible and provide repeatable positioning for automated CMM inspection.
Solution
Designed a precision inspection fixture with specialized features:
- 316 stainless steel construction (cleanroom-compatible)
- Kinematic coupling for repeatable positioning
- Soft contact points to prevent surface damage
- Integrated datum simulators
- Full material certification and biocompatibility docs
Results
±0.002mm
Repeatability
75%
Faster Inspection
100%
FDA Compliant
Engine Block High-Precision Machining Process Control and Quality Assurance
Challenge
An automotive supplier needed a multi-station welding fixture for producing structural frame components with 8 weld joints. The fixture had to accommodate part variation while maintaining weld joint gap tolerances of ±0.3mm.
Solution
Engineered a robust welding fixture with adjustable clamps:
- Modular 4-station design for production efficiency
- Adjustable locating pins for part variation
- Pneumatic clamps with force control
- Heat-treated tool steel construction
- Quick-change tooling for different part variants
Results
4x
Production Capacity
±0.25mm
Weld Gap Control
95%
Weld Quality Rate
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