Case studies
Projects and how we solved them
Representative work from our machining, casting and reverse engineering floors — the problem, the route we chose and the measured outcome.
Automotive transmission housing
Problem
A tier supplier needed a low-volume transmission housing with bore alignment held across three faces, but their existing vendor could not repeat the concentricity between batches.
Solution
We machined the housing in two 5-axis set-ups instead of four 3-axis operations, holding all critical bores from a single datum scheme and proving the fixture with a first article before batch release.
| Detail | Specification |
|---|---|
| Process | 5-axis CNC milling |
| Material | Aluminium 6061-T6 |
| Tolerance | ±0.01 mm on bores |
| Lead time | 12 working days |
| Result | Zero rejects across repeat batches |
Obsolete textile machine spare
Problem
A processing plant lost a 30-year-old cast bracket with no drawings available and no supplier still producing the machine.
Solution
The worn original was 3D scanned, the geometry rebuilt as parametric CAD, worn surfaces restored to nominal and the replacement machined from solid to avoid tooling cost on a single part.
| Detail | Specification |
|---|---|
| Process | 3D scanning + CNC milling |
| Material | Alloy steel 4140 |
| Tolerance | ±0.02 mm |
| Lead time | 9 working days |
| Result | Drop-in fit, machine back in service |
Die cast LED heat sink
Problem
A lighting OEM needed a fixture body that dissipated heat adequately at a cost that extruded and machined options could not reach at their annual volume.
Solution
We designed the die with the fin geometry and draft required for casting, cast in ADC12, then finish machined the LED mounting face and threaded bosses in-house before powder coating.
| Detail | Specification |
|---|---|
| Process | High-pressure die casting + CNC |
| Material | ADC12 aluminium |
| Tolerance | ±0.05 mm cast, ±0.02 mm machined |
| Lead time | Tool 5 weeks, parts 10 days |
| Result | Unit cost reduced against machined baseline |
Hardened press tooling set
Problem
A sheet metal fabricator was losing edge quality as punches wore prematurely on a high-cycle progressive tool.
Solution
Punches and dies were wire cut from hardened tool steel, ground to final size and clearance re-specified for the material thickness, with spares produced in the same batch.
| Detail | Specification |
|---|---|
| Process | Wire cut EDM + grinding |
| Material | Hardened tool steel |
| Tolerance | ±0.005 mm on profile |
| Lead time | 14 working days |
| Result | Longer cycle life between regrinds |
Have a similar challenge?
Send the part, the problem and the volume — we will tell you the most economical route to make it.