Real Projects — Verified Results

CNC Machining Case Studies

Real projects. Actual parts. Measurable results. From single prototypes to 12,000-piece annual contracts — here's what we deliver for global OEM customers.

0%
Customer Rejection Rate
500K+
Parts Delivered
15+
Countries Supplied
24h
RFQ Response Time
CASE STUDY — EV MANUFACTURING

12,000 EV Battery Enclosure Covers — 18-Month Contract, Zero Rejections

A European electric vehicle platform OEM required high-volume aluminum 6061-T6 battery enclosure covers for their next-generation EV platform. The challenge: consistent flatness, precision M3 thread inserts, hard-coat anodize finish, and a rolling 4-week delivery schedule to their German assembly plant.

The Challenge

  • +/-0.01 mm flatness over 280 mm length — verified by CMM on 100% of parts
  • 12× M3 thread inserts per cover — pull-out tested per DIN spec
  • Hard-coat anodize Type III, 25 μm minimum — coordinated with certified local anodizer
  • PPAP Level 2 documentation approved on first submission
  • Rolling 4-week delivery schedule via FedEx to Germany

The Result

12,000 parts delivered over 18 months. 0% rejection rate. PPAP approved first time. Customer extended contract for a second platform.

IndustryElectric Vehicles
Customer LocationGermany
MaterialAluminum 6061-T6
Quantity12,000 pcs over 18 months
Tolerance+/-0.01 mm flatness
FinishHard-coat Anodize Type III
CNC machined aluminum battery enclosure covers for EV manufacturing
Precision CNC machined stainless steel parts for medical diagnostic equipment
CASE STUDY — MEDICAL DEVICES

500 Stainless Steel Diagnostic Instrument Bodies — +/-0.005 mm Critical Bores

A US medical device manufacturer needed 500 pieces of a stainless steel 316L instrument body for a diagnostic system. The part required +/-0.005 mm tolerance on two critical bore diameters, specific surface finish (Ra 0.4 μm on sealing surfaces), and full FAI documentation.

The Challenge

  • +/-0.005 mm tolerance on 12 mm and 18 mm precision bores
  • Ra 0.4 μm on sealing surfaces — achieved by fine boring and honing
  • 100% CMM inspection on all critical features
  • EN 10204 3.1 material cert for SS 316L raw material
  • FAI package with full dimensional report, material cert, and CoC
  • 12-day delivery from order confirmation

The Result

500 parts delivered in 12 days. All critical features within tolerance. FAI approved first submission. Customer placed repeat order for 1,500 more.

IndustryMedical Devices
Customer LocationUSA
MaterialStainless Steel 316L
Quantity500 pcs
Tolerance+/-0.005 mm critical bores
Lead Time12 business days
CASE STUDY — INDUSTRIAL AUTOMATION

5-Axis Aluminum Brackets for Robotic Arm System — DFM Saved Two Design Iterations

An Israeli industrial automation company needed 200 complex aluminum 7075-T6 brackets for a new robotic arm system. The initial design had features that would have required three setups on a 3-axis machine — our DFM review suggested a minor design change that allowed single-setup 5-axis machining, reducing cost by 22% and lead time by 4 days.

The Challenge

  • Complex compound-angle pockets originally requiring 3 setups
  • DFM redesign: minor corner radius change enabled full 5-axis, single setup
  • 22% unit cost reduction vs. original design
  • Anodized black finish for corrosion protection
  • On-time delivery for system integration milestone

The Result

200 parts delivered on schedule. Customer credited DFM feedback with saving two full design iterations. Ongoing supply arrangement established.

IndustryIndustrial Automation
Customer LocationIsrael
MaterialAluminum 7075-T6
Quantity200 pcs
Process5-Axis CNC Milling
FinishAnodize Black
5-axis CNC machined aluminum brackets for robotic arm system

What Our Customers Say

★★★★★
"Robocon supplied 8,000 aluminum motor housing covers for our EV platform over 12 months. Zero rejections. CMM reports matched our spec exactly. We've extended the contract."
Engineering ManagerEV Component OEM — Germany
★★★★★
"We needed +/-0.005 mm on critical bores for diagnostic instruments. Robocon delivered 500 pcs in 12 days with full FAI documentation. Exceptional quality from India."
Procurement DirectorMedical Device Manufacturer — USA
★★★★★
"Their DFM feedback saved us two design iterations. The 5-axis machined brackets arrived perfectly finished, on schedule, and under budget."
R&D EngineerIndustrial Automation Company — Israel

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