Project Overview
We manufactured complex structural brackets for an aerospace assembly. The goal was to maximize strength while minimizing weight, requiring intricate pocketing and thin-wall machining.
Challenge
Machining Titanium Grade 5 is notoriously difficult due to its hardness and heat retention. The part featured complex organic curves and deep pockets that required 5-axis simultaneous machining to avoid multiple setups and ensure accuracy.
Our Solution
We selected specialized carbide end mills with AlTiN coating for heat resistance and optimized tool paths using Mastercam to maintain constant chip load. This prevented work hardening and ensured dimensional stability.
Results
•Achieved a 30% weight reduction
•Maintained structural integrity under load tests
•Zero defects across the entire batch
•Passed all FAA-compliant stress tests
