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.
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.
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.
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.
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."
"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."
"Their DFM feedback saved us two design iterations. The 5-axis machined brackets arrived perfectly finished, on schedule, and under budget."
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