Learn more about how we leveraged our 5-axis machining capabilities to manufacture a complex component in a single operation.
Component Application: This precision-machined component interfaces an industrial 6-axis robot with a custom end effector. It is part of a larger assembly project for an OEM of specialized warehousing and manufacturing equipment.
Customer Problem: This part’s geometry was complex to reduce component weight and increase robot speed and payload. Additionally, this component had challenging geometric requirements to ensure proper alignment between the robot and the end effector. In addition to these requirements, hard coat anodizing was required on multiple critical surfaces, requiring strategic under-sizing of features to account for plating growth. Our customer struggled to reliably source this component since it required challenging geometric alignment of features that could not be machined or measured in a single operation on traditional 3-axis or 4-axis horizontal machining centers.
LHM Solution:
To ensure proper alignment of all features, we developed a unique process to machine the entire part in a single operation utilizing our 5-axis machining equipment. The part was left complete on a single 0.75mm tab (see picture below) with only a minor cleanup operation required on a single noncritical surface. This strategy allowed all critical features to be machined simultaneously to ensure proper alignment of part datums. Additionally, it eliminated the need for fixtures, which reduced the cost and lead time of the project.
We developed a modified pre-plating CAD model for programming and in-process verification to account for surface growth during hard coat anodizing. We then used in-process machine probing to verify feature size and location before surface treatment.
Masking and hard coat anodizing was completed through a trusted vendor in our robust network of subcontractors. Once we received the parts back from plating, we leveraged our temperature-controlled quality lab with CMM measuring capabilities to verify all required specifications before shipment, ensuring the highest quality and reliability.