Check out our gallery of solutions to difficult part challenges. From exotic metals and materials to complex shapes – we’re ready to tackle your next challenging job.
Challenge: This part has a bore diameter tolerance of “plus” .0005 with an extremely close concentricity callout to an opposing counter bore. The thin walls in the “cone” area along with the large cutouts make it difficult to hold the tolerances in an “un-restrained” condition. Material: Titanium. Size: 2.125” x 3.5”
Challenge: This very complex part with over 1,200 dimensions features critical seal surfaces, compound angles, and extremely close tolerances with over 150 installed heli-coils. Material: Aluminum, chem-filmed plated. Size: 2.75” x 9” x 11.75”
Challenge: The raw material for this part is glass filled – making these abrasive, very thin and flimsy walls very difficult to cut. Material: NORYL (Plastic). Size: 1.75” x 2.5” x 5.5”
Challenge: This chassis features deep pockets and small radii with the primary datum being held flat within .001”. Adding to the complexity of the part was extensive masking, painting and installing over 100 heli-coils. Material: Aluminum, chem-filmed, masked and painted. Size: 2.25” x 13.375” x 11.125”
Challenge: This part features very deep pockets with welded covers, critical seal surfaces and finishes. TBM developed a process to maintain the tight tolerances even after the titanium welding operation. Material: Titanium. Size: 2.5” x 2.375” x 5.5”
Challenge: Very thin walls with extremely close tolerances are featured in this part, with many dimensions adjusted to allow for the anodize plating buildup of just .0003 per side. What’s more, intricate masking was required to paint the internal walls with light absorbing material. Material: Black anodized aluminum Size: 2.75” x 9” x 11.75”