Multi-Component CNC Machining for a Custom Robotic Sorting System

Summary

The client required a complete kit of custom-machined components for a new robotic sorting machine prototype. By providing an integrated manufacturing solution for four unique parts and offering key DFM feedback, we delivered a full set of components with guaranteed fitment, consistent finishes, and a 25% reduction in their final assembly time.

The Challenge

Initial Need:

The client was developing a complex robotic system that required a custom-built frame and actuator mounts. The design involved a family of four distinct parts: aluminum pipe clamps for the main structure, curved support arms for a conveyor belt guide, flat mounting plates for sensors, and steel shaft hubs for the drive motors.

Pain Points:

The primary challenge was supplier management and ensuring interoperability. Using multiple machine shops would risk inconsistent surface finishes, tolerance stacking issues between mating parts, and complex project management. They needed a single, reliable partner who could produce the entire "kit of parts" to a high standard.

Our Solution

Final Summary:

We managed the production of all four components concurrently. The aluminum parts (clamps, arms, plates) were machined from 6061-T6 stock on our 3 and 4-axis CNC mills. The shaft hubs were CNC turned from 1045 carbon steel bar stock, with the keyways and set screw holes added in a secondary milling operation. By controlling the entire manufacturing process, we ensured all parts shared a consistent clear anodized finish (aluminum) and black oxide coating (steel), and that all interfacing dimensions were perfectly matched.

Outcome

Project Details