Industry: Construction Equipment – USA

Challenge:

• Converted from billet machining to investment casting
• Redesigned geometry to reduce machining by 38%
• Optimized wall thickness

Result:

• 28% cost reduction
• 40% reduction in machining time
• Lead time reduced by 2 weeks

Industry: Agriculture Equipment – Europe

Challenge:

• Multiple bore alignments and GD&T within 25 microns

Solution:

• Used 3-axis and 4-axis CNCs
• Custom machining fixtures
• 100% CMM inspection for pilot lot

Result:

• 100% PPAP approval on first submission
• Zero rejections over 10,000+ pcs

Industry: Oil & Gas – Middle East

Challenge:

• No drawing or CAD available
• Damaged sample provided

Solution:

• 3D scanning and CAD modeling
• Spectro material analysis
• Pattern development and sample delivery in 3 weeks

Result:

• Fitment approved
• Lead time saved: 10–12 weeks

Industry: Electric Vehicle – Germany

Challenge: Weight reduction of 20% required on cast iron part

Solution:

• Redesigned in Aluminum LM6 with FEA validation
• Gravity die casting and ribbed structure

Result:

• 26% weight reduction
• Passed fatigue & vibration tests

Industry: Thermal Equipment – India

Challenge: Operation at 750°C with high-speed performance

Solution:

• Used HK40 steel and solution annealing
• 4-axis machining and dynamic balancing

Result:

• Service life doubled
• Complied with ISO G6.3 tolerance

Industry: Automation & Robotics – South Korea

Challenge: Internal helical groove with ±10 micron bore tolerance

Solution:

• Live tooling with CBN inserts
• Custom coolant enclosure for thermal stability

Result:

• Ra < 0.4 µm finish
• Annual order for 50,000 pcs secured