DFM Analysis for Precision CNC Machined Aerospace Components
Summary
AeroTech Industries faced excessive machining costs and long lead times for critical flight control components. Complex geometries required specialized tooling and multiple setups, driving costs 340% above target.
The Challenge
Initial Need:
AeroTech Industries needed DFM optimization for flight control actuator housings with machining costs 340% above target due to complex geometries requiring 12 different setups, specialized tooling, and extensive manual finishing operations.
Pain Points:
Multiple setups increasing cycle time and tolerance stack-up
Specialized tooling costs of $45K per component variant
Lead times exceeding 16 weeks due to scheduling complexity
Quality issues from tolerance accumulation across setups
Our Solution
Our Approach:
Geometric redesign to enable 5-axis simultaneous machining in single setup, standardized tool library utilization, optimized surface finish specifications, and integrated datum reference system to eliminate secondary operations while maintaining aerospace quality standards.
Methodology:
CAM simulation using Mastercam X9, tool path optimization, fixturing analysis, surface finish requirements review, and prototype validation with CMM inspection to verify dimensional accuracy and AS9100 compliance requirements.
Final Summary:
Optimized design enabled single 5-axis setup with standard tooling, achieving 78% cost reduction, 85% cycle time improvement, and 100% first-pass quality while exceeding all aerospace structural and environmental requirements.
Execution
Process Description:
Implementation utilized Haas UMC-750 5-axis machining center with pallet changer, standardized workholding, automated tool management, and in-process gauging for 100% dimensional verification without manual intervention.
Outcome
Value Comparison:
Machining costs reduced by 78%, lead time reduced from 16 weeks to 3 weeks, setup time reduced by 92%, and achieved 100% on-time delivery while maintaining aerospace quality standards and reducing tooling investment by $540K annually.
Client Testimonial:
"The DFM approach revolutionized our manufacturing approach and enabled us to compete effectively in the aerospace market while maintaining our quality reputation."
- Chief Engineer, AeroTech Industries