Aerospace Structural Bracket Program

How 5-axis CNC machining reduced lead times by 40% and eliminated quality issues for a critical aerospace structural component program.

Challenge

An aerospace Tier 1 supplier was experiencing quality issues and extended lead times with their existing supplier for a complex structural bracket. The component featured compound angles, tight tolerances (±0.02mm), and required machining on five faces. Multiple setups were introducing positional errors, and reject rates were running at 8%.

Solution

CNC Industries proposed a 5-axis single-setup approach that eliminated repositioning errors and reduced cycle time. Our engineering team conducted a full DFM review, identifying opportunities to optimise toolpaths and reduce non-cutting time while maintaining all critical tolerances.

Approach

Comprehensive Design for Manufacturability (DFM) review
Custom 5-axis fixturing for single-setup machining
Optimised CAM programming for reduced cycle time
In-process gauging for critical features
CMM inspection protocol with full dimensional reporting

Results

Lead Time Reduction: 40% — Reduced from 4 weeks to 2.5 weeks through single-setup 5-axis machining
Quality Improvement: 99.6% — First-pass yield improved from 92% to 99.6% by eliminating repositioning errors
Cost Reduction: 25% — Lower piece price through reduced cycle time and eliminated rework
Parts Delivered: 2,400+ — Ongoing production program with monthly scheduled deliveries

Materials

Aluminium 7075-T651, Titanium Grade 5

Capabilities Used

5-Axis CNC Machining, CMM Inspection, First Article Inspection