Project Overview
Detailed look at our work with a global TOP3 automotive brand
Project Summary
A global TOP3 automotive brand required complex engine components with tight tolerances of ±0.005mm and challenging material (Inconel 718). These components were critical to engine performance and required exceptional precision and quality.
Challenge
The global automotive brand required complex engine components with tight tolerances of ±0.005mm and challenging material (Inconel 718). The components were critical to engine performance and required exceptional precision and quality.
Specific challenges included:
- Complex geometries with tight tolerances
- Difficult-to-machine Inconel 718 material
- High volume production requirements (10,000+ parts)
- Stringent quality standards with minimal defect allowance
- Competitive delivery timeline
Solution
We utilized our advanced 5-axis machining centers with specialized tooling and custom fixtures to achieve the required precision for these complex components.
Our approach included:
- Advanced CAM programming for optimal tool paths
- Custom fixtures designed specifically for this component
- Specialized cutting tools for Inconel 718 machining
- In-process inspection to ensure dimensional accuracy
- Dedicated production team with extensive experience in automotive components
Results
We successfully delivered over 10,000 components with 99.97% quality compliance, exceeding the client's expectations for both quality and delivery timeline.
Key outcomes:
- 99.97% quality compliance rate
- 20% faster delivery than competition
- Became preferred supplier for additional components
- Client reported improved engine performance metrics
- Zero warranty claims on delivered components